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OM-272989A

2016

−

Multimatic 215

Visit our website at

www.MillerWelds.com

Processes

Description

Multiprocess Welding

Arc Welding Power Source
Wire Feeder

File: Multiprocess

Содержание Multimatic 215

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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