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Miller Millermatic 211 Auto-Set, Owner'S Manual

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Miller Millermatic 211 Auto-Set Owner'S Manual Download Page 4

TABLE OF CONTENTS

SECTION 7 

−

 MAINTENANCE &TROUBLESHOOTING

31

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7-1. Routine Maintenance

31

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7-2. Overload Protection

31

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7-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

31

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7-4. Troubleshooting Table

32

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SECTION 8 

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 ELECTRICAL DIAGRAM

34

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SECTION 9 

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 GMAW WELDING (MIG) GUIDELINES

36

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SECTION 10 

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 PARTS LIST

44

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COMPLETE PARTS LIST 

−

 Available at www.MillerWelds.com

WARRANTY

Summary of Contents for Millermatic 211 Auto-Set

Page 1: ...Millermatic 211 Processes OM265809B 2016 01 Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding File MIG GMAW Visit our website at www MillerWelds com R ...

Page 2: ...ontinue 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 the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ...10 4 1 Serial Number And Rating Label Location 10 4 2 Unit Specifications 10 4 3 Environmental Specifications 10 4 4 Duty Cycle And Overheating 11 4 5 Volt Ampere Curves 12 SECTION 5 INSTALLATION 13 5 1 Selecting A Location 13 5 2 Multi Voltage Plug MVP Connection 14 5 3 Electrical Service Guide 15 5 4 Connecting 120 Volt Input Power 15 5 5 Connecting 1 Phase Input Power For 240 VAC 16 5 6 Install...

Page 4: ...1 7 2 Overload Protection 31 7 3 Drive Motor Protection And Tip Saver Short Circuit Protection 31 7 4 Troubleshooting Table 32 SECTION 8 ELECTRICAL DIAGRAM 34 SECTION 9 GMAW WELDING MIG GUIDELINES 36 SECTION 10 PARTS LIST 44 COMPLETE PARTS LIST Available at www MillerWelds com WARRANTY ...

Page 5: ...neeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work...

Page 6: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw frozen pipes D ...

Page 7: ...S can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and...

Page 8: ...FPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational 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 intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there...

Page 9: ...ement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol Dans ces conditions utiliser les équipements suivants dans l ordre indiqué 1 un poste à souder DC à tension constante à fil 2 un...

Page 10: ... des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflammables à une distance de 10 7 m de l arc de soudage En cas d impossibilité les recouvrir soigneusementavec des p...

Page 11: ...appareil D Tenir l équipement câbles et cordons à distance des véhicules mobiles lors de toute opération en hauteur D Suivre les consignes du Manuel des applications pour l équation de levage NIOSH révisée Publication Nº94 110 lors du levage manuelle de pièces ou équipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT D Prévoir une période de refroidissement res pecter le cycle opératoi...

Page 12: ...l ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied...

Page 13: ...ions before working on the machine or welding Safe40 2012 05 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on CE products A Amperage Direct Current DC Alternating Current AC V Voltage Gas Input Circuit Breaker I2 Rated Welding Current I1max Rated Maximum Supply Current U1 Primary Voltage Positive Negative Hz Hertz U0 Rated No Load Voltage OCV U2 Conventional Load Voltage Li...

Page 14: ...rage Range Maximum Open Circuit Voltage DC U0 Amperes Input at Rated Load Output 50 60HZ Single Phase KVA KW Weight w Gun Overall Dimensions 120 VAC 115 A 19 8 Volts DC 20 Duty Cycle 30 130 54 24 3 2 9 2 9 42 lb 19 kg Length 20 5 in 521 mm Width 11 25 in 286 mm Height 12 5 in 318 mm Wire Type and Dia Solid Stainless Flux Cored Wire Feed Speed Range 023 035 in 0 6 0 9 mm 030 035 in 0 8 0 9 mm 60 60...

Page 15: ... cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Continuous Welding Continuous Welding 2 Minutes Welding 8 Minutes Resting 4 Minutes Welding 6 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 272269A 20 duty cycle at 115 amps 40 duty cycle at 150 amps 240V 120V 20A Duty Cycle 10 20 30 40 50 60 70 80 90 1...

Page 16: ...Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown 272270A 120 240V MIN 240V MAX 120V MAX Amperes 0 0 20 Volts 40 60 80 100 25 50 75 100 125 150 175 200 225 ...

Page 17: ...lation 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 Line Disconnect Device Locate unit near correct input power supply 18 in 460 mm 18 in 460 mm 2 Do not move or operate unit where it could tip Movement Location And Airflow 1 loc_smallmig 2015 12 ...

Page 18: ...eptacle NEMA Type 6 50R Customer Supplied Follow electrical service guide for 240 VAC in Section 5 3 Do not use plug rating to size branch circuit protection Connecting Plug To Power Cord Align arrow on plug with arrow on power cord connector Push together Tighten threaded collar As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle MVP ...

Page 19: ...n place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboa...

Page 20: ... is available on line at www MillerWelds com OM265809 Page 16 5 5 Connecting 1 Phase Input Power For 240 VAC input4 2012 05 271714A 803766C Ref 802443A Tools Needed L1 L2 240 VAC 1 8 2 1 L1 L2 1 GND PE Earth Ground 6 5 3 4 7 ...

Page 21: ...nd check input volt age available at site 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals 5 Black And White Input Conductor L1 And L2 6 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 ...

Page 22: ...rformance and ex cessive heating of the work clamp 1 Work Clamp 2 Work Cable From Unit 3 Screw 4 Flat Washer 5 Lock Washer 6 Nut Route work cable through hole in clamp handle Secure cable with hardware as shown 805460A 2 6 1 Tools Needed 3 4 5 5 7 Work Cable Routing Inside Unit Ref 267805A 1 Work Cable 2 Output Terminal Block Work cable is routed through the small hole in front panel and routed al...

Page 23: ...ielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal 5 9 Changing Polarity Always read and follow wire manufacturer s recommended polarity and see Section 5 8 Ref 267805A Ref 267825A Connection hardware must be tightened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and excess...

Page 24: ...cle Route gun trigger plug through front panel Insert plug into receptacle and tighten threaded collar 4 Gun Securing Knob 5 Gun End Loosen knob Insert end of gun through opening in front panel until it bottoms against drive assembly Tighten knob Close door Correct Incorrect 2 5 5 4 1 5 3 Be sure that gun end is tight against drive assembly Incorrect installation will have adverse effects on gas f...

Page 25: ...rive roll includes three different sized grooves The text aligned with the drive roll retaining pin indicates the selected groove see Section 5 13 3 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retainingpin then rotate drive roll to desired slot See Section 10 2 for optional drive rolls 024 Groove 030 035 Groove 030 035 V Knurled Groove Groove Compatible ...

Page 26: ...ting Hub Tension When a slight force is needed to turn spool tension is set 1 2 in Tools Needed 803012 267865A Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool ten sion is set Align locking hole in spool with locking pin on spool hub Adapter and retainingring ...

Page 27: ... off wire Close door Press gun trigger until wire comes out of gun Keep gun cable as straight as possible Be sure that tip matches wire diameter Reinstall contact tip and nozzle Turn power on Tighten Use pressure indicator to set a desired drive roll pressure Begin with a setting of 2 If necessary make additional adjustments after trying this initial setting Pressure Indicator Tighten Close and ti...

Page 28: ...g power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open feedhead pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 20 to 25 cfh cubic feet per hour Check wire manufacturer s recommended flow rate 8 CO2 Adapter Customer Supplied 9 O Ring Customer Supplied Install adapter with O rin...

Page 29: ...Replace With A Spool Gun Open Pressure Assembly Hold wire tightly to keep it from unraveling Rewind Wire Onto Spool Fasten End Of Wire To Spool Cut Off End Of Wire Loosen Knob Disconnect Gun Trigger Plug And Remove Gun From Unit See Section 5 10 for gun installation 270208A Ref 802982A Ref 267805A Ref 267807A Knob Turn Off Power ...

Page 30: ...t left control knob to 2 Set right control knob to 70 Pull spool gun trigger and hold until wire stops feeding Spool gun should feed 24 in of wire Measure the length of wire If wire length is greater than 24 in turn right control knob counterclockwise 10 If wire length is less than 24 in turn left control knob clockwise 10 Pull trigger and feed wire again Measure and repeat adjustment until 24 in ...

Page 31: ...esired weld process 3 Wire Speed Wire Diameter Control Turn control clockwise inside white scale 10 100 to increase wire feed speed see weld parameter chart in welding power source or Section 6 4 4 Over Temperature Light If unit overheats light turns on and output stops Allow unit to cool before resuming operation This light will also communicate additionalunit errors 5 Power Light Power light ill...

Page 32: ...o Set LED indicates pa rameter is not recommended 4 Voltage Material Thickness Control Adjust the Voltage Material Thickness control knob to the desired steel material thickness to weld There is no adjustment within the material thickness band 265381A 4 2 3 1 6 3 Jog Mode If gun trigger is held for longer than 3 seconds without initiating a weld arc unit will enter Jog mode and disable weld output...

Page 33: ... A complete Parts List is available on line at www MillerWelds com OM265809 Page 29 6 4 Weld Parameter Chart 267705A ...

Page 34: ... A complete Parts List is available on line at www MillerWelds com OM265809 Page 30 6 5 Weld Parameters Ref 267705A ...

Page 35: ... Reset supplementary protector 1 7 3 Drive Motor Protection And Tip Saver Short Circuit Protection A Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative cycle unit power off and back on again B Tip Saver Short Circuit Protection The tip saver short circuit protection extends contact tip life and protects internal components fr...

Page 36: ...gun Owner s Manual Oversized tip may be required for some wires Clean or replace wire inlet guide or liner if dirty or plugged see Section 5 11 or gun Owner s Manual Replace drive roll or pressure bearing if worn or slipping see Section 5 11 Secure gun trigger plug see Section 5 10 Check and clear any restrictions at drive assembly and liner see Section 5 11 or gun Owner s Manual Release gun trigg...

Page 37: ...OM265809 Page 33 Notes ...

Page 38: ...OM265809 Page 34 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 39: ...OM265809 Page 35 265 808 E ...

Page 40: ...comply to specifications 3 5 x 125 A 437 ipm 2 x 125 A 250 ipm 1 6 x 125 A 200 ipm 30 90 A 40 145 A 50 180 A Convert Material Thickness to Amperage A Material thickness determines weld parameters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in 3 5 in pe...

Page 41: ... and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS 9 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 Slow F...

Page 42: ...t 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 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer ...

Page 43: ... in weld metal S 0635 Possible Causes Corrective Actions Insufficient 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 nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding...

Page 44: ...welding power source 9 12 Troubleshooting Incomplete Fusion 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 paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Im...

Page 45: ...ort hand on solid surface or use two hands 9 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower vo...

Page 46: ... Pass Welding Only 4 90 HE 7 1 2 AR 2 1 2 CO2 5 Also for GMAW P All Positions 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 wire feed rolls replace to match wire size and ty...

Page 47: ...ting Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip...

Page 48: ...ocoil 035 045 wire x 15ft consisting of 1 079975 O RING 187 ID x 103CS rbr 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 10 2 Optional Drive Rolls For All Feed Head Assemblies PART NO WIRE DIAMETER INCHES mm 261157 024 6 and 030 035 8 and ...

Page 49: ...Notes ...

Page 50: ...Notes ...

Page 51: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 52: ...h 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 Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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