Miller Millermatic 210 Owner'S Manual Download Page 1

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Processes

Description

Arc Welding Power Source
and Wire Feeder

OM-1325

204 902M

2005

−

Visit our website at

www.MillerWelds.com

Millermatic 210

And M-25 Gun

Flux Cored (FCAW) Welding

MIG (GMAW) Welding

File: MIG (GMAW)

Summary of Contents for Millermatic 210

Page 1: ...es Description Arc Welding Power Source and Wire Feeder OM 1325 204 902M 2005 09 Visit our website at www MillerWelds com Millermatic 210 And M 25 Gun R Flux Cored FCAW Welding MIG GMAW Welding File M...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...Gun Duty Cycle And Overheating 10 4 4 Volt Ampere Curves 11 4 5 Connecting To Weld Output Terminals 11 4 6 Installing Work Clamp 12 4 7 Installing Welding Gun 12 4 8 Connecting An Optional Spool Gun 1...

Page 4: ...ics 35 8 7 Good Weld Bead Characteristics 35 8 8 Troubleshooting Excessive Spatter 36 8 9 Troubleshooting Porosity 36 8 10 Troubleshooting Excessive Penetration 36 8 11 Troubleshooting Lack Of Penetra...

Page 5: ...147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input...

Page 6: ...bustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher...

Page 7: ...computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly...

Page 8: ...ccupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent o...

Page 9: ...la norme OSHA 29 CFR 1910 147 voir normes de s curit D Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provi...

Page 10: ...poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur pro...

Page 11: ...t provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs D Demander seulement des personnes qualifi es familiaris es avec...

Page 12: ...art Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312...

Page 13: ...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 5 31 2 2 1 27 1 1 8 6 36 0 51 5...

Page 14: ...peres 3 Minutes Welding 7 Minutes Resting 4 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...

Page 15: ...rt a fire or damage your ma chine 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal...

Page 16: ...tion with boot Close door Ref 802 474 D Tools Needed 3 4 in 3 2 1 4 7 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob Insert gun end through opening until it...

Page 17: ...al Close door 3 802 998 B 1 2 4 4 9 Setting Gun Polarity For Wire Type 1 Polarity Changeover Label Information Always read and follow manufac ture s recommended polarity 1 3 4 11 16 in Ref 190 821 A C...

Page 18: ...tical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For Spool Gun 7 Welding Power Source Gas Hose Connection For MIG Gun Connect gas hose between regulator flowm...

Page 19: ...16 in Use compression spring with 8 in 200 mm spools Tools Needed 072573 B 802 922 Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the procedure as shown in the illu...

Page 20: ...in Grounding Conductor Size In AWG 4 10 10 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time...

Page 21: ...2 Plug NEMA Type 6 50P 3 Receptacle NEMA Type 6 50R Customer Supplied 4 Input Power Cord Connect directly to line disconnect device if hard wiring is required 5 Black And White Input Conductor L1 And...

Page 22: ...and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until...

Page 23: ...Page 19 802 726 1 Side Panel 2 Latch 3 Cable Holder Press latch down to release and open door 4 Holster 2 Wrap cable around cable holder and place gun nozzle into holster 1 2 4 16 Using Gun Cable Hol...

Page 24: ...increase voltage 2 Wire Speed Control Set Wire Speed control according to the parameterchart Increase or decrease wire speed to obtain desired bead profile and travel speed 3 Power Switch This switch...

Page 25: ...OM 1325 Page 21 Notes...

Page 26: ...s 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 this char...

Page 27: ...OM 1325 Page 23 204 890...

Page 28: ...grease to drive motor shaft Ref 802 990 6 2 Supplementary Protector CB1 1 SupplementaryProtector CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive As...

Page 29: ...rew Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two differ ent sized grooves The stamped markings on the end surface of the dri...

Page 30: ...turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Ref 800 412 A Correct Incorrect 4 3 2 1 5 Tools Needed 6 7 Removing Knob From Front Panel Y Turn Off...

Page 31: ...n new liner Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Y Disconnect gun from unit first Tools Needed Lay gun cable out straight before...

Page 32: ...e with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing...

Page 33: ...or low line voltage see Section 4 14 Low high or erratic wire speed Readjust front panel settings see Section 5 1 Change to correct size drive roll see Section 6 5 Readjust drive roll pressure see Sec...

Page 34: ...OM 1325 Page 30 SECTION 7 ELECTRICAL DIAGRAM 204 891 A Figure 7 1 Welding Power Source Circuit Diagram...

Page 35: ...urrent 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 Wire Feeder Power Source Workpiece Gun Regul...

Page 36: ...035 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ip...

Page 37: ...3 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradl...

Page 38: ...trode 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 WELD BEAD PROFILES ELECTRODE EXTENS...

Page 39: ...nt Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Sli...

Page 40: ...sufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozz...

Page 41: ...Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pain...

Page 42: ...pport hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the...

Page 43: ...ed Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire fe...

Page 44: ...essary 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 welding power source Readjust welding parameters...

Page 45: ...OM 1325 Page 41 Notes...

Page 46: ...SECTION 9 PARTS LIST Hardware is common and not available unless listed 802 993 C 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 1 Fig 9 2 2 Fig 9 3 18 Fig 9 4 19 Fig 9 5 Figure 9 1...

Page 47: ...12 FT 030 035 1 20 196328 CABLE WORK 10 NO 3 W CLAMP INCLUDING 1 130750 CLAMP WORK 300 AMP 1 600318 CABLE WELD COP STRD NO 3 EPDM JKT ORDER BY FT 10FT 196318 COVER CABLE BTRY POST BLK 75 ID 1 21 0916...

Page 48: ...OM 1325 Page 44 802 989 A Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 14 15 13 16 17 18 20 19 21 22 24 25 26 27 23 Fig 9 6 Figure 9 2 Baffle Center w Components...

Page 49: ...12SQ 500 HIGH 4 16 PC1 204 807 CIRCUIT CARD ASSY CONTROL 1 PLG4 131056 HOUSING RECEPTACLE SOCKETS 1 PLG6 115092 HOUSING PLUG SOCKETS 1 134201 STAND OFF SUPPORT PC CARD 312 375W POST LOCK 43 4 17 TE1 1...

Page 50: ...137761 NUT 750NPT 1 31HEX 27H NYL BLK 1 2 148809 BLADE FAN 9 000 5WG 34DEG 312 BORE CCW PLSTC 1 3 188706 MOTOR FAN 230V 50 60HZ 1550 RPM 312 DIA SHAFT 1 4 203711 WINDTUNNEL 9 000 1 5 222508 VALVE 34V...

Page 51: ...K50X 20 PAN HD PHL STL PLD PT THREAD FORMING 4 7 S1 124511 SWITCH TGL DPST 40A 600VAC SCR TERM WIDE TGL 1 8 C7 8 9 10 14 15 136735 CAPACITOR CER DISC 1UF 500VDC STRIP 6 9 048282 RECEPTACLE W SOCKETS 2...

Page 52: ...OM 1325 Page 48 Ref 800 792 C 1 2 3 4 5 6 7 8 9 10 15 18 11 12 11 12 13 9 16 17 14 Figure 9 5 M 25 Gun...

Page 53: ...170 467 RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 169 732 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 1...

Page 54: ...X 1 15 079633 FITTING HOSE BRS BARBED M 3 16TBG 1 16 601966 SCREW 375 16 X 1 25HEXHD 2 17 604538 WASHER FLAT STL SAE 312 1 18 204585 KNOB 1 19 173619 CARRIER DRIVE ROLL W COMPONENTS 1 20 174609 SCREW...

Page 55: ...ored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Ref S 0026 B 7 91 Wire Diameter Fraction Decimal Metric 030 035 in 030 i...

Page 56: ...Notes...

Page 57: ...Notes...

Page 58: ...Notes...

Page 59: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Page 60: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal S...

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