Miller Millermatic 210 User Manual

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - TABLE OF CONTENTS; WARNING

TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.

OM-1325 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards

OM-1325 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly sized,...

Page 8 - EMF Information

OM-1325 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining mo...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-1325 Page 5 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 procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un messag...

Page 10 - LE BRUIT peut affecter l’ouïe.

OM-1325 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer des...

Page 13 - SECTION 2 – INSTALLATION; Welding Power Source And MIG Gun Specifications; A or V

OM-1325 Page 9 SECTION 2 – INSTALLATION 2-1. Welding Power Source And MIG Gun Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Amperage Range DC Max. Open Circuit Voltage DC 200 (208) V 230 V KVA KW 160 A at 24.5 VDC, 60% Duty Cycle 210 A at 23 VDC 30% Duty Cycle 30-210 34...

Page 14 - MIG Welding Gun Duty Cycle And Overheating; CAUTION

OM-1325 Page 10 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 Duty Cycle is percentage of 10minut...

Page 16 - Connecting An Optional Spool Gun; Setting Gun Polarity For Wire Type; Changing Polarity; Work Clamp Lead

OM-1325 Page 12 2-7. Connecting An Optional Spool Gun 1 Barbed Fitting . If spool gun gas hose isequipped with a pre-installedbarbed fitting, cut off fitting fromend of hose. Connect spool gun gas hose tobarbed fitting. 2 Gun Trigger Plug Insert plug into receptacle labeled“SPOOL GUN”, and tightenth...

Page 17 - Installing Gas Supply

OM-1325 Page 13 2-9. Installing Gas Supply 802 028-A / Ref. 802 991 Tools Needed: Obtain gas cylinders and chain torunning gear, wall, or otherstationary support so cylinderscannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side ofvalve, and open valve slightly. Gasflow bl...

Page 18 - -10. Installing MIG Wire Spool and Adjusting Hub Tension

OM-1325 Page 14 2-10. Installing MIG Wire Spool and Adjusting Hub Tension 072573-B When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with8 in (200 mm) spools. Tools Needed:

Page 20 - -13. Selecting A Location And Connecting Input Power

OM-1325 Page 16 2-13. Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power. 2 Plug (NEMA Type 6-50P) 3 Receptacle(NEMA Type 6-50R) Connect plug to receptacle. 4 Input And GroundingConductors Connect directly to line disconnectdevice if hard wiring is required. 5 ...

Page 23 - SECTION 3 – OPERATION; Controls; ON

OM-1325 Page 19 SECTION 3 – OPERATION 3-1. Controls 1 Voltage Control Set Voltage control according to theparameter chart for good starting point.Turn control clockwise to increase voltage. 2 Wire Speed Control Set Wire Speed control according to theparameter chart. Increase or decrease wirespeed to...

Page 24 - Weld Parameter Chart

OM-1325 Page 20 3-2. Weld Parameter Chart Input Line Voltage* Parameter Chart Settings Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC Weld Will Be Hotter Lower Settings Use Parameter Chart Inside Door Weld Will Be Colder Raise Settings *Line voltage can affect weld output, settings on...

Page 26 - SECTION 4 – MAINTENANCE &TROUBLESHOOTING; Routine Maintenance; Months; Circuit Breaker CB1

OM-1325 Page 22 SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. 3 Months Replace unreadable labels Repair or replacecracked weld cable Clean and tighten weld terminals 6 Months Blow out or vac...

Page 28 - Aligning Drive Rolls and Wire Guide

OM-1325 Page 24 4-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look-ing down with pressure assemblyopen. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver, and turn screwin or out until drive roll groove lin...

Page 29 - Cleaning Or Replacing Gun Liner

OM-1325 Page 25 4-7. Cleaning Or Replacing Gun Liner Ref. 800 797-C 5/16 in, 10 mm To Reassemble Gun: Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in[9.5 mm] for aluminum) from headtube. Install adapter, contact tip, andnozzle. Y Disconnect gun from unit first. Tools Needed: Lay ...

Page 30 - Replacing Switch And/Or Head Tube

OM-1325 Page 26 4-8. Replacing Switch And/Or Head Tube Ref. 800 795-C 1 Remove handlelocking nut. 2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, and secure with handle locking...

Page 31 - Troubleshooting

OM-1325 Page 27 4-9. 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 res...

Page 32 - SECTION 5 – ELECTRICAL DIAGRAM; Figure 5-1. Welding Power Source Circuit Diagram

OM-1325 Page 28 SECTION 5 – ELECTRICAL DIAGRAM 204 891 Figure 5-1. Welding Power Source Circuit Diagram

Page 33 - Typical MIG Process Connections

OM-1325 Page 29 SECTION 6 – MIG WELDING (GMAW) GUIDELINES 6-1. Typical MIG Process Connections Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. Wire Feeder/ Power Source Workpiece Gun Reg...

Page 34 - Typical MIG Process Control Settings; NOTE

OM-1325 Page 30 6-2. Typical MIG Process Control Settings 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 tospecifications. NOTE 1/8 or .125 in Material thickness determines weldparameter...

Page 35 - Holding And Positioning Welding Gun

OM-1325 Page 31 6-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet andpressing 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. NOTE 1 Hold Gun and Control GunT...

Page 36 - Conditions That Affect Weld Bead Shape

OM-1325 Page 32 6-4. Conditions That Affect Weld Bead Shape 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. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND W...

Page 37 - Gun Movement During Welding; Poor Weld Bead Characteristics

OM-1325 Page 33 6-5. 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 ormultiple stringer beads works better. NOTE 1 Stringer Bead – SteadyMovement Along Seam 2 W...

Page 40 - -14. Troubleshooting – Waviness Of Bead

OM-1325 Page 36 6-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not coverjoint 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) be...

Page 41 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment

OM-1325 Page 37 6-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table. Application Gas Spr...

Page 43 - Notes

Page 44 - SECTION 7 – PARTS LIST

OM-1325 Page 40 SECTION 7 – PARTS LIST . Hardware is common andnot available unless listed. 802 993 1 Fig. 7 – 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Fig. 7 – 4 18 19 20 21 23 24 26 22 25 17 Fig. 7 – 5 2 Fig. 7 – 3 Figure 7-1. Main Assembly

Page 53 - Table 7-1. Drive Roll And Wire Guide Kits; Note

OM-1325 Page 49 Table 7-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing type...

Page 55 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 56 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...