Miller Multimatic 215 Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SAFETY PRECAUTIONS - READ BEFORE USING

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1-2. Arc Welding Hazards

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

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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

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

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Informations relatives aux CEM

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SECTION 3

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DEFINITIONS

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3-1. Additional Safety Symbols And Definitions

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3-2. Miscellaneous Symbols And Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Serial Number And Rating Label Location

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4-2. Unit Specifications For MIG (GMAW)

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4-3. Unit Specifications For TIG (GTAW)

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4-4. Unit Specifications For Stick (SMAW)

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4-5. Environmental Specifications

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4-6. Dimensions And Weight

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4-7. Duty Cycle And Overheating For MIG (GMAW)

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4-8. Duty Cycle And Overheating For TIG (GTAW)

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4-9. Duty Cycle And Overheating For Stick (SMAW)

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SECTION 5

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INSTALLATION

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5-1. Selecting A Location

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5-2. Multi

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Voltage Plug (MVP) Connection

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5-3. Electrical Service Guide

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5-4. Extension Cord Data

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5-5. Connecting 120 Volt Input Power

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5-6. Connecting 1-Phase Input Power For 240 VAC

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5-7. Stick Welding Connections

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5-8. TIG Welding Connections DCEN (Direct Current Electrode Negative)

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5-9. Process/Polarity Table

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5-10. MIG Welding Connections

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5-11. MIG Gun Connection Inside Unit

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5-12. Connecting Shielding Gas Supply

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5-13. Installing Wire Spool And Adjusting Hub Tension

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5-14. Threading Welding Wire

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5-15. Removing MIG Gun To Replace With A Spool Gun

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Summary of Contents for Multimatic 215

Page 1: ...OM 272989A 2016 03 Multimatic 215 Visit our website at www MillerWelds com Processes Processes Description Multiprocess Welding Arc Welding Power Source Wire Feeder File Multiprocess t...

Page 2: ...ntinue 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: ...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 11 4 5 Environmental Specifications 11 4 6 Dimensions A...

Page 4: ...14 Control Software Menu 10 Of 10 39 SECTION 7 MAINTENANCE TROUBLESHOOTING 40 7 1 Routine Maintenance 40 7 2 Overload Protection 40 7 3 Changing Drive Roll Or Wire Inlet Guide 41 7 4 Error Messages 42...

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...

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 clo...

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 ma...

Page 8: ...PA 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...

Page 9: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Page 10: ...br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier et s assur...

Page 11: ...areil D Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Page 12: ...ational 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 Cy...

Page 13: ...lectric 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 ma...

Page 14: ...e X Duty Cycle Line Connection S Suitable for Some Hazardous Locations Increase Hz Hertz Single Phase Static Frequency Converter Transformer Rectifier Lift Arc GTAW TIG Remote Wire Feed Slow Run In Ga...

Page 15: ...8 16 7 Wire Type And Dia Solid Stainless Flux Cored Wire Feed Speed Range 023 035 in 0 6 0 9 mm 030 045 in 0 8 1 2 mm 60 600 IPM 1 5 15 2 m min 4 3 Unit Specifications For TIG GTAW Do not use informat...

Page 16: ...MillerWelds com OM 272989 Page 12 20 1 2 in 521 mm 4 6 Dimensions And Weight 275173A 11 1 4 in 286 mm 12 1 2 in 318 mm 38 lb 17 2 kg Weight Notes Work like a Pro Pros weld and cut safely Read the saf...

Page 17: ...en minutes for unit to cool Reduce amperage or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6 Minutes Resting 2 Minutes Weld...

Page 18: ...heats output stops Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6 M...

Page 19: ...rheats output stops Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6...

Page 20: ...on 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 inp...

Page 21: ...le 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 pl...

Page 22: ...ted Output 29 3 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 35 Normal Operating Fuses 3 40 Min Input Conductor Size In AWG 4 14 Max Recommended Input Conductor Length In Feet...

Page 23: ...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 240 VAC See rating label on unit and check in...

Page 24: ...is available at www MillerWelds com OM 272989 Page 20 5 6 Connecting 1 Phase Input Power For 240 VAC input4 2012 05 803 766 C Ref 802 443 A 275173A Tools Needed L1 L2 240 VAC 1 8 2 1 L1 L2 1 GND PE E...

Page 25: ...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 Whit...

Page 26: ...nect input power before making connections 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Stick Electrode Holder And Cable 4 Work Clamp And Cable Connect stick electrode holder...

Page 27: ...eceptacle 3 TIG Torch And Cable 4 Work Clamp And Cable Connect TIG torch cable to the negative weld output receptacle and connect work cable to positive weld output receptacle Ensure all connections a...

Page 28: ...unit and disconnect input power before making connections 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Wire Drive Assembly Cable 4 Work Clamp And Cable Ensure all connections...

Page 29: ...oosen knob Insert end of gun through opening in front panel until gun end bottoms against gun block Tighten knob 5 Trigger Control Cable 6 Four Pin Trigger Control Cable Receptacle Route trigger contr...

Page 30: ...g 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 Typ...

Page 31: ...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 803 012 803 013 B Ref 802 444 C Installing 8 in 203 mm Wire Spool Installing 4 in 102...

Page 32: ...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 wire comes out of gun Reinstall contact tip and nozzl...

Page 33: ...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...

Page 34: ...ungsten 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 se lected Wire Rod Tungsten buttons are used to select t...

Page 35: ...A complete Parts List is available at www MillerWelds com OM 272989 Page 31 6 2 Welding Parameter Chart 120V Wire Drive Lead Work Lead Work Lead Wire Drive Lead Ref 272942 B...

Page 36: ...A complete Parts List is available at www MillerWelds com OM 272989 Page 32 6 3 Welding Parameter Chart 240V Ref 27294 B Wire Drive Lead Work Lead Work Lead Wire Drive Lead...

Page 37: ...nd Material Thickness Plus button After entering the setup menu the Material Thickness light will flash To move to the next setup menu press the Material Thickness Plus button To move to the previous...

Page 38: ...at 500 IPM turn right Adjustment knob and verify that a check mark appears next to 500 IPM Wait for the lock symbol to change from un locked to locked Be sure wire is cut flush at nozzle then trigger...

Page 39: ...igger the Spoolmate Spoolmatewill feed approximately 24 in of wire through gun Cut wire flush at nozzle and mea sure run out If wire length is not 24 in use left Adjustment knob to increase de crease...

Page 40: ...e as the weld wire speed To exit menu simultaneously press and release the Wire Rod Tung sten Minus button and Material Thickness Plus button or turn unit off and on Ref 271491A 1 2 3 6 9 Process Logs...

Page 41: ...d Tung sten Minus button and Material Thickness Plus button or turn unit off and on Ref 271491A 1 2 6 11 Error Logs Menu 7 Of 10 1 Material Thickness Minus Button 2 Material Thickness Plus Button Foll...

Page 42: ...will all be retained Follow instructions in Section 6 4 to enter the setup menu To perform a Factory Reset press the Auto Set button To exit menu simultaneously press and release the Wire Rod Tung st...

Page 43: ...Menu 10 Of 10 Control Software information is for factory and service use only Follow instructions in Section 6 4 to enter the setup menu To exit menu simultaneously press and release the Wire Rod Tu...

Page 44: ...ing severe conditions n Check Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Eve...

Page 45: ...he drive roll includes three different sized grooves The text aligned with the drive roll retaining pin indicates the selected groove 3 Retaining Pin To secure drive roll locate open slot and push dri...

Page 46: ...error The 4 pin or 8 pin trigger is held during TIG preflow for more than 10 seconds Release the 4 pin or 8 pin triggers Shorted output First remove short then pull trigger to clear error The welding...

Page 47: ...primary voltage is below 90 volts Increase primary voltage above 90 volts Network error Communication between micros has been lost The two microcontrollers on the control board are no longer communic...

Page 48: ...nd correct poor connections to workpiece Fan not operating Unit not warmed up enough to require fan cooling Check for and remove anything blocking fan movement Have Factory Authorized Service Agent ch...

Page 49: ...OM 272989 Page 45 Notes...

Page 50: ...OM 272989 Page 46 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram...

Page 51: ...OM 272989 Page 47 272984 A...

Page 52: ...omply 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 i...

Page 53: ...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...

Page 54: ...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 Slig...

Page 55: ...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 sp...

Page 56: ...elding 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 Action...

Page 57: ...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 w...

Page 58: ...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...

Page 59: ...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 volt...

Page 60: ...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 Ar...

Page 61: ...T 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...

Page 62: ...o 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 Characteristi...

Page 63: ...wide groove weld joints or bridging across 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 Pa...

Page 64: ...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 thick...

Page 65: ...ve 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 Exce...

Page 66: ...e 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 Se...

Page 67: ...11 to 35 CFH cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 11 2 Preparing Tungsten Electrode For...

Page 68: ...mentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4...

Page 69: ...h 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 rod Welding direction 15 12 3 Positioning Torch Tungst...

Page 70: ...e x 15ft consisting of 1 194012 Liner monocoil 035 045 wire x 15ft consisting of 1 079975 O RING 187 ID x 103CS rbr 1 To maintain the factory original performance of your equipment use only Manufactur...

Page 71: ...ns 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 suc...

Page 72: ...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 Equip...

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