Miller Multimatic 200 Owner'S Manual Download Page 3

Page: 3 / 68

TABLE OF CONTENTS

SAFETY PRECAUTIONS - READ BEFORE USING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2

−

CONSIGNES DE SÉCURITÉ

−

LIRE AVANT UTILISATION

. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symboles utilisés

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

. . . . .

2-4. Proposition californienne 65 Avertissements

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de sécurité

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Informations relatives aux CEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3

−

DEFINITIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Additional Safety Symbols And Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Miscellaneous Symbols And Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4

−

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Serial Number And Rating Label Location

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Unit Specifications For MIG (GMAW)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Unit Specifications For TIG (GTAW)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Unit Specifications For Stick (SMAW)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Environmental Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Dimensions And Weight

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Duty Cycle And Overheating For MIG

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Duty Cycle And Overheating For TIG

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Duty Cycle And Overheating For Stick

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5

−

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Selecting a Location

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Stick Welding Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative)

. . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Process/Polarity Table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Wire Welding Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Wire Gun Connection Inside Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting Shielding Gas Supply

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Multi

−

Voltage Plug (MVP) Connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Selecting Cable Sizes*

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Electrical Service Guide

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Input Power Extension Cord Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Connecting 120 Volt Input Power

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13. Connecting 1-Phase Input Power For 230 VAC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14. Installing Wire Spool And Adjusting Hub Tension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15. Threading Welding Wire

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for Multimatic 200

Page 1: ...19 01 Multimatic 200 Processes Processes Description Multiprocess Welding Arc Welding Power Source Wire Feeder File Multiprocess For product information Owner s Manual translations and more visit www MillerWelds com ...

Page 2: ...products continue 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 a...

Page 3: ...rial Number And Rating Label Location 11 4 2 Unit Specifications For MIG GMAW 11 4 3 Unit Specifications For TIG GTAW 11 4 4 Unit Specifications For Stick SMAW 12 4 5 Environmental Specifications 12 4 6 Dimensions And Weight 12 4 7 Duty Cycle And Overheating For MIG 13 4 8 Duty Cycle And Overheating For TIG 14 4 9 Duty Cycle And Overheating For Stick 15 SECTION 5 INSTALLATION 16 5 1 Selecting a Lo...

Page 4: ...Menu 9 Of 10 36 6 13 Performing A Factory Reset Menu 10 Of 10 37 SECTION 7 MAINTENANCE TROUBLESHOOTING 38 7 1 Routine Maintenance 38 7 2 Overload Protection 38 7 3 Changing Drive Roll Or Wire Inlet Guide 39 7 4 Error Messages 39 7 5 Troubleshooting 40 SECTION 8 ELECTRICAL DIAGRAM 42 SECTION 9 GMAW WELDING MIG GUIDELINES 44 SECTION 10 STICK WELDING SMAW GUIDELINES 52 SECTION 11 SELECTING AND PREPAR...

Page 5: ... electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling 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 semiautomatic DC con...

Page 6: ...not possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling fl...

Page 7: ...to move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING D Allow cooling period follow r...

Page 8: ... George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standa...

Page 9: ...nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliques telles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé...

Page 10: ...udure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et 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 inflamma...

Page 11: ...e mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire D Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil D En utilisant des fourches de levage pour déplacer l unité s...

Page 12: ...ing Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02169 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 ...

Page 13: ...95 2012 05 Beware of electric shock from wiring Safe94 2012 08 When power is applied failed parts can explode or cause other parts to explode Safe26 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes aft...

Page 14: ...reaker Positive U2 Conventional Load Voltage U0 Rated No Load Voltage OCV X Duty Cycle Self Shielded Flux Cored Arc Welding SMAW Alternating Current AC I2 Rated Welding Current Negative Line Connection Gas Metal Arc Welding GMAW S Suitable for Some Hazardous Locations Lift Arc GTAW TIG Remote V Voltage Increase Shielded Metal Arc Welding SMAW Hz Hertz Single Phase Static Frequency Converter Transf...

Page 15: ...A 17 75 Volts DC 100 Duty Cycle 30 140 90 22 4 14 6 Wire Type And Diameter Solid Stainless Flux Cored Wire Feed Speed Range 023 035 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 70 425 IPM 1 75 10 8 m min 230 VAC 150 A 21 5 Volts DC 20 Duty Cycle 120 A 20 Volts DC 100 Duty Cycle 30 200 90 17 5 13 1 Wire Type And Diameter Solid Stainless Flux Cored Wire Feed Speed Range 023 035 in 0 6 0 9 mm 030 045 in 0 8 1...

Page 16: ...aximum Open Circuit Voltage DC Amperes Input at Rated Load Output 50 60 Hz Single Phase 120 VAC 100 A 24 Volts DC 35 Duty Cycle 70 A 22 8 Volts DC 100 Duty Cycle 20 100 90 23 8 16 5 230 VAC 150 A 26 Volts DC 30 Duty Cycle 100 A 24 Volts DC 100 Duty Cycle 20 150 90 20 8 12 7 CSA Rating 4 5 Environmental Specifications A Temperature Specifications Operating Temperature Range Storage Transportation T...

Page 17: ...uty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 2 Minutes Welding 8 Minutes Resting 2 Minutes Welding 8 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 20 Duty Cycle At 110A Continuous Welding 100 Duty Cycle At 75A 120V Input 230V Input 20 Duty Cycle At 150A Continuous Welding 100 Duty Cycle...

Page 18: ...ycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 3 Minutes Welding 7 Minutes Resting 3 Minutes Welding 7 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 30 Duty Cycle At 150A Continuous Welding 120V Input 100 Duty Cycle At 75A 230V Input 30 Duty Cycle At 150A Continuous Welding 100 Duty Cycle At 1...

Page 19: ...e before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 3 Minutes Welding 7 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 35 Duty Cycle At 100A Continuous Welding 120V Input 100 Duty Cycle At 70A 230V Input 30 Duty Cycle At 150A Continuous Welding 100 Duty Cycle At 100A 3 1 2 Minutes Welding 6 1 2 Minutes...

Page 20: ...vice Locate unit near correct input power supply Movement Location And Airflow 2 18 in 460 mm 18 in 460 mm 1 5 2 Stick Welding Connections Ref 254 251 B Turn off unit and disconnect input power before making connections Do not use worn damaged undersized or repaired cables 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Stick Electrode Holder And Cable 4 Work Clamp And Cable ...

Page 21: ...2 Negative Weld Output Receptacle 3 TIG Torch And Cable 4 Work Clamp And Cable Connect TIG torch cable to the negative weld output receptacle and connect work clamp to positive weld output receptacle Ensure all connections are tight 5 Foot Control 6 Finger Tip Control 7 Remote Control Cable 8 Six Pin Remote Control Receptacle Route control cable through MIG gun hole Connect foot control or finger ...

Page 22: ...input power before making connections Do not use worn damaged under sized or repaired cables 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Wire Drive Assembly Cable 4 Work Clamp And Cable Ensure all connections are tight 5 Gun End Connect gun end to drive assembly see Section 5 6 6 Trigger Control Cable 7 Four Pin Trigger Control Cable Receptacle Route trigger control cable...

Page 23: ... Loosen knob Insert end of gun through openingin front panel until gun end bottoms against gun block Tighten knob 5 Trigger Control Cable 6 Four Pin Trigger Control Cable Receptacle Route trigger control cable through MIG gun hole Connect plug on end of cable to four pin receptacle inside unit Correct Incorrect Be sure that gun end is tight against drive assembly 4 4 Ref 801 987 3 6 5 2 1 4 ...

Page 24: ... Power Source Argon Gas Hose Connection Connect gas hose between regulator flowmeter gas hose connection and the appropriate fitting for the gas type on rear of welding power source 8 Flow Adjust Typical flow rate for CO2 shielding gas and MIG GMAW welding is 15 to 30 CFH cubic feet per hour and mixed gas is 25 to 45 CFH Typical flow rate for Argon shielding gas and TIG GTAW welding is 15 to 25 CF...

Page 25: ...le NEMA Type 6 50R Customer Supplied Follow electrical service guide for 230 VAC in Section 5 10 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 Plug...

Page 26: ...tection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 50 60 Hz Single Phase 50 60 Hz Single Phase Input Voltage V 230 120 Input Amperes A At Rated Output 17 7 A 15 or 20 ampere indiv...

Page 27: ...ticle 511 or CEC Section 20 NOTICE The Auto Line circuitry in this unit automatically links the power source to the primary voltage being applied either 120 or 230 VAC See rating label on unit and check input voltage available at site For 120 volts AC input power a 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 1 Multi Voltage Plug And Power ...

Page 28: ... is available at www MillerWelds com OM 253392 Page 24 5 13 Connecting 1 Phase Input Power For 230 VAC input4 2012 05 803 766 C Ref 802 443 A 253 921 B Tools Needed L1 L2 230 VAC 1 8 2 1 L1 L2 1 GND PE Earth Ground 6 5 3 4 7 ...

Page 29: ...heck 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 and ...

Page 30: ...slight force is needed to turn spool tension is set 1 2 in Tools Needed Ref 254 253 C 803 012 803 013 B Ref 802 444 C Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set Retaining ring used with 8 in 203 mm spool only Adapter used with 8 in 203 mm spool only Align locking hole in spool with locking pin on spool hub 2 1 ...

Page 31: ... 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 wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Ref 254 253 C 254 249 C 801 083 Ref 800 924 D Tighten 1 2 3 4 Pressure Indicator Scale T...

Page 32: ...Buttons Press the Plus or Minus button to select the size of wire rod or tungsten for the selected process When MIG Aluminum process is selected Wire Rod Tung sten buttons are used to select type of spool gun being used 4 Material Thickness Buttons Press the Plus or Minus button to select material thickness for the selected process 5 Display 6 Adjustment Knob 7 Power Switch Use switch to turn unit...

Page 33: ... A complete Parts List is available at www MillerWelds com OM 253392 Page 29 6 2 Weld Parameter Chart 252671 H ...

Page 34: ... Material Thickness Plus Button 3 Display When unit is turned off press and hold Wire Rod Tungsten Minus button and Material Thickness Plus button simultaneously Turn unit power on When Display shows MULTIMATIC 200 setup screen release the two buttons simultaneously The contrast adjustment screen should be displayed Ref 249 632 F 1 2 3 ...

Page 35: ...ast turn either Adjustment knob Cycle through menu items using the Material Thickness Plus button or cycle unit power to save settings and exit menu Cycle unit power before welding to complete initialization process Ref 249 632 F 1 1 2 6 5 Calibrating Drive Motor Menu 2 Of 10 The unit s internal drive motor is calibrated at the factory No calibration is needed unless drive motor or user interface ...

Page 36: ...re that wire is cut flush at nozzle then trigger the Spoolmate Spoolmatewill feed approximately 24 in of wire through gun Cut wire flush at nozzle and measure run out If wire is not 24 inches long use left Adjustment knob to increase or de crease the length of the run out and repeat the test To perform a Spoolmate calibration 24 in runout test at 300 ipm turn right Adjustment knob and verify that ...

Page 37: ...hickness Plus but ton three times after entering setup to enter the Auto Crater feature menu Auto Crater is disabled by default Rotate adjustment knob clockwise to enable Auto Crater Rotate adjustment knob counterclock wise to disable Auto Crater Cycle through menu items using the Material Thickness Plus button or cycle unit power to save settings and exit menu Cycle unit power before welding to c...

Page 38: ...erial Thickness Plus button five times after entering setup to enter the Software information screen Software information displays software information unique to the unit Cycle through menu items using the Material Thickness Plus button or cycle unit power to save settings and exit menu Cycle unit power before welding to complete initialization process 6 10 Viewing Primary Power Information Menu 7...

Page 39: ...en times after entering setup to enter the Process Logs screen Process Logs screen displays manual minutes Auto Set minutes weld cycles and Auto Set cycles for the selected process To view other processes use the Process Select knob to select the desired weld process Cycle through menu items using the Material Thickness Plus but ton or cycle unit power to save set tings and exit menu Cycle unit po...

Page 40: ...ss Plus button eight times after entering setup to enter the Process Logs screen Error Logs screen displays unit over temperature errors shorted out put errors shorted trigger errors input voltage errors and input current er rors Cycle through menu items using the Material Thickness Plus button or cycle unit power to save settings and exit menu Cycle unit power before welding to complete initializ...

Page 41: ...tings Spoolmate Calibration set tings Burn In information and Software information will all be retained Follow instructions in Section 6 3 to enter the setup menu Press Material Thickness Plus button nine times after entering setup to enter the Factory Reset screen To perform a Factory Reset press the Auto Set button To exit this screen without performing a factory reset press the Material Thickne...

Page 42: ... during severe conditions n Check Z Change Clean l Replace To be done by Factory Authorized Service Agent Every 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Every 6 Months OR Inside Unit Clean Drive Rolls 7 2 Overload Protection 253 923 B 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 ...

Page 43: ...er Electric Mfg LLC service department CABLE ERROR The microcontroller on the user interface board is no longer communicating with the microcontroller on the control board Connect the wire drive assembly cable to either the positive or negative stud or select a different process A process that requires a welding gun to not be attached to the internal motor is selected but the wire drive assembly c...

Page 44: ...sary or reset supplementary protector Be sure power cord is plugged in and that receptacle is receiving input power No weld output unit is on Check and secure loose weld cable s into receptacle s Check and correct poor connection of work clamp to workpiece Unit overheated causing thermal shutdown Allow unit to cool with fan On see Sections 4 7 4 8 and 4 9 Reduce duty cycle or amperage Check and co...

Page 45: ...OM 253392 Page 41 Notes ...

Page 46: ...OM 253392 Page 42 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 47: ...OM 253392 Page 43 264 018 A ...

Page 48: ...ess to amperage A 0 001 in 0 025 mm 1 ampere 0 0625 in 1 59 mm 0 001 62 5 A 2 Select Wire Size See table below 3 Select Wire Feed Speed Amperage Wire feed speed amperage controls weld pene tration See table below 4 Select Voltage Voltage controls height and width of weld bead Low Voltage wire stubs into work High Voltage arc is unstable spatter Set voltage midway between high and low voltage 1 16 ...

Page 49: ...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 3 Holding And Positioning Welding Gun Slow Fillet Weld Electode Extensions Stickout Electrode Extensions Stickout Gun Angles And Weld Bead Profiles 10 10 S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Weld bead shape d...

Page 50: ...se weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 5 Gun Movement During Welding 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 51: ... 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 52: ...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 53: ...port 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 v...

Page 54: ...Circuiting Stainless Steel Spray Arc Aluminum Short Circuiting Aluminum GMAW P Argon All Positions All Positions All Positions Argon 1 O2 Flat Horizontal Fillet Flat Horizontal Fillet All Positions Argon 2 O2 Flat Horizontal Fillet Flat Horizontal Fillet All Positions Argon 5 CO2 Flat Horizontal Fillet All Positions Argon 10 CO2 Flat Horizontal Fillet All Positions All Positions Argon 25 CO2 All P...

Page 55: ...ch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Lo...

Page 56: ...ess current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 10 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound Correct arc length is related to electrode di ameter Examine the weld b...

Page 57: ...ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER MED 10 3 Striking An Arc S 0049 S 0050 Weld current starts when elec trode touches workpiece 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift elect...

Page 58: ...To produce the best results hold a short arc travel at a uniform speed and feed the electrode downward at a constant rate as it melts 1 1 2 2 Groove Welds Fillet Welds 10 5 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 10 6 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Unifor...

Page 59: ...ross gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the elec trode Do not let weave width ex ceed 2 1 2 times diameter of electrode 1 2 3 10 8 Electrode Movement During Welding 10 9 Welding Lap Joints S 0063 S 0064 1 Electrode 2 ...

Page 60: ...re good welds The single or double V groove weld is good for materials 3 16 3 4 in 5 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thickness you can weld from one side only Create a 30 degree bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels 30...

Page 61: ...ive Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electro...

Page 62: ...se and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes C...

Page 63: ...ngstens 010 in 25 mm Up to 15 Up to 15 020 in 50 mm 5 20 5 20 040 in 1 mm 15 80 15 80 1 16 in 1 6 mm 70 150 70 150 3 32 in 2 4 mm 150 250 140 235 1 8 in 3 2 mm 250 400 225 325 5 32 in 4 0 mm 400 500 300 400 3 16 in 4 8 mm 500 750 400 500 1 4 in 6 4 mm 750 1000 500 630 Typical argon shielding gas flow rates are 10 to 25 CFH cubic feet per hour Figures listed are a guide and are a composite of recom...

Page 64: ...l radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Ideal Tungsten Preparation Stable Arc 1 Grinding Wheel Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality 2 Tungsten Electrode A 2 ceria...

Page 65: ... 261157 0 024 6 0 030 0 035 0 8 and 0 9 Standard and 0 030 0 035 0 8 and 0 9 VK Groove 220179 0 024 0 6 and 0 030 0 035 0 8 and 0 9 Standard 202926 0 030 0 035 0 8 and 0 9 and 0 045 1 2 VK Groove Optional 12 2 MDX Welding Gun Consumables See OM 282976 shipped with this product for information on replacement consumables for the MDX welding gun ...

Page 66: ...Notes ...

Page 67: ...ssemblies TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessories Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45...

Page 68: ...th 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...

Search results

Summary of Contents for Multimatic 200

Reviews:

Related manuals for Multimatic 200

Brands by name

Popular brands

Miller Multimatic 200, Owner'S Manual

Search results

Summary of Contents for Multimatic 200

Reviews:

Related manuals for Multimatic 200

Brands by name

Popular brands