Miller Multimatic 215 User Manual

Page 2 - To locate your nearest; Thank you; 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 distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1...

Page 5 - ELECTRIC SHOCK can kill.

OM-272989 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020 − 02 7 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 not avoided, will ...

Page 6 - FUMES AND GASES can be hazardous.; ARC RAYS can burn eyes and skin.; WELDING can cause fire or explosion.; BUILDUP OF GAS can injure or kill.

OM-272989 Page 2 Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D Ventilate the work area and/or use local forced ventilation at the arc to remove weldin...

Page 7 - BATTERY EXPLOSION can injure.

OM-272989 Page 3 Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. D Protect compressed gas cylinders from excessive heat, mech...

Page 9 - SECTION 2; CONSIGNES DE SÉCURITÉ; UNE DÉCHARGE ÉLECTRIQUE peut

OM-272989 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020 − 02_fre 7 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. Symboles utilis...

Page 12 - -4. Proposition californienne 65 Avertissements

OM-272989 Page 8 LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’instal- lation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange...

Page 13 - -1. Additional Safety Symbols And Definitions; Notes

OM-272989 Page 9 SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions 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 ...

Page 14 - -2. Miscellaneous Symbols And Definitions; IP

OM-272989 Page 10 3-2. Miscellaneous Symbols And Definitions A Amperage V Voltage U 0 Rated No Load Voltage (OCV) Direct Current (DC) Alternating Current (AC) U 1 Primary Voltage U 2 Conventional Load Voltage I 2 Rated Welding Current Input Power Or In- put Voltage Gas Input IP Internal Protection R...

Page 15 - SECTION 4; -1. Serial Number And Rating Label Location; -3. Information About Default Weld Parameters And Settings

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 11 SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements and/o...

Page 17 - A or V

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 13 4-9. Duty Cycle And Overheating For MIG (GMAW) 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 ampe...

Page 20 - SECTION 5

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 16 SECTION 5 − INSTALLATION 5-1. Selecting A Location ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 1 Lifting Handles Use handles to lift unit.2...

Page 25 - Pros weld and cut

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 21 input4 2012 − 05 − 803 766-C ! Installation must meet all National and Local Codes − have only qualified per- sons make this installation. ! Disconnect and lockout/tagout input power before connecting input con- ductors fr...

Page 31 - -13. Installing Wire Spool And Adjusting Hub Tension

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 27 5-13. Installing Wire Spool And Adjusting Hub Tension 1 Wire Spool 2 Retaining Nut − For 8 in. (203 mm) Spool Only When a slight force is needed to turn spool, tension is set. 1/2 in. Tools Needed: Ref. 275174A / 803 012 /...

Page 33 - -15. Removing MIG Gun To Replace With A Spool Gun

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 29 5-15. Removing MIG Gun To Replace With A Spool Gun Open Pressure Assembly. . Hold wire tightly to keep itfrom unraveling. Rewind Wire Onto Spool, Fasten End Of Wire To Spool. Cut Off End Of Wire. Loosen Knob, Disconnect Gu...

Page 34 - SECTION 6

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 30 SECTION 6 − OPERATION 6-1. Controls 1 Process Select Button Press up and down buttons to select de- sired welding process.2 Auto-Set Button Press button to turn Auto-Set On or Off.3 Wire/Rod/Tungsten Buttons Press the Plus...

Page 44 - SECTION 7

. A complete Parts List is available at www.MillerWelds.com OM-272989 Page 40 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more oftenduring severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factory...

Page 52 - SECTION 9; Typical GMAW (MIG) Process Control Settings

OM-272989 Page 48 SECTION 9 − GMAW WELDING (MIG) GUIDELINES Wire Feeder/ Welding Power Source Workpiece Gun Regulator/ Flowmeter Gas Shielding Gas Work Clamp 9-1. Typical GMAW (MIG) Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before weld...

Page 53 - Holding And Positioning Welding Gun; Conditions That Affect Weld Bead Shape

OM-272989 Page 49 . Welding wire is energized whengun 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. 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 E...

Page 54 - Gun Movement During Welding

OM-272989 Page 50 . Normally, a single stringerbead 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. 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side To Side Movemen...

Page 57 - Waviness Of Bead; Distortion

OM-272989 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...

Page 59 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment

OM-272989 Page 55 9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, but wire does not feed. Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Incorrect wire feed rolls. Check size stamped on wir...

Page 61 - 0-2. Electrode And Amperage Selection Chart

OM-272989 Page 57 10-2. Electrode And Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 N...

Page 63 - 0-7. Conditions That Affect Weld Bead Shape

OM-272989 Page 59 S-0061 Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle Electrode Angle Arc Length Travel Speed . Weld bead shape is affectedby electrode angle, arc length, travel speed, and thickness of base metal. 10-7. Conditions ...

Page 67 - Wear Clean Gloves To Prevent Contamination Of Tungsten

OM-272989 Page 63 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 Tungst...

Page 68 - Or AC Welding With Inverter Machines

OM-272989 Page 64 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 ...

Page 70 - 2-3. Positioning Torch Tungsten For Various Weld Joints

OM-272989 Page 66 12-2. Torch Movement During Welding 162002-B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove ...

Page 71 - PARTS LIST

OM-272989 Page 67 SECTION 13 − PARTS LIST . A complete Parts List is available on-line at www.MillerWelds.com 13-1. Drive Rolls For All Feed Head Assemblies Part No. Wire Diameter - in. (mm) 261157 .024 (.6) and .030/.035 (0.8 and 0.9) and .030/.035 (0.8 and 0.9) (VK Groove) ♦ 220179 .024 (.6) and ....

Page 75 - (Equipment with a serial number preface of NA or newer); Call

Effective January 1, 2020 (Equipment with a serial number preface of NA 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 below, Miller Electri...

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ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2020 − 01 Miller Electric Mfg. LLC An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 Internati...