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==Description==

==Description==

The Millermatic 210 is a wire feed metal inert gas (MIG) welder that is meant for light industrial use. Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding torch, which shields the process from contaminants in the air. This is the easiest and most common type of welding which makes it perfect for those learning to weld. It uses 72/25 CO2 and Argon gas mixture to shield the molten weld from oxygen. If the weld pool is exposed to oxygen, it can create a handful of problems such as porosity and excessive spatter in the bead. This welder is capable of welding carbon steel as well as stainless steel. Below is a short video explaining MIG welding. Before completing the training on this machine you must complete the [[Virtual Reality Welding Station]] training and spend some time practicing with it to get a feel for the welding process. This purpose of this wiki is to explain the operation of the Millermatic 210 not the actual welding technique which is learned on the VR Welder. {{#evu:https://www.youtube.com/watch?v=twUAa5LWUvk}}

The Millermatic 210 is a wire feed metal inert gas (MIG) welder that is meant for light industrial use. Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. This is the easiest and most common type of welding which makes it perfect for those learning to weld. It uses 72/25 CO2 and Argon gas mixture to shield the molten weld from oxygen. If the weld pool is exposed to oxygen, it can create a handful of problems such as porosity and excessive spatter in the bead. This welder is capable of welding carbon steel as well as stainless steel. Below is a short video explaining MIG welding. Before completing the training on this machine you must complete the [[Virtual Reality Welding Station]] training and spend some time practicing with it to get a feel for the welding process. This purpose of this wiki is to explain the operation of the Millermatic 210 not the actual welding technique which is learned on the VR Welder. {{#evu:https://www.youtube.com/watch?v=twUAa5LWUvk}}

==Documentation==

==Documentation==

====Terminology====

====Terminology====

* MIG Welding - Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding torch, which shields the process from contaminants in the air.

* MIG Welding - Metal inert gas is a welding process in which an electric arc forms between a consumable MIG wire electrode and the base metal, which heats the base metal, causing them to melt and join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air.

* Weld Metal/Electrode - The metal added to the base metal to create a weld.

* Weld Metal/Electrode - The metal added to the base metal to create a weld.

* Torch - The piece that is held while welding and feeds the weld metal into the base metal.

* Gun - The piece that is held while welding and feeds the weld metal into the base metal.

* Base metal - The metal pieces that are being joined together.  

* Base metal - The metal pieces that are being joined together.  

* Coupons - Small pieces of metal used to practice welding.

* Coupons - Small pieces of metal used to practice welding.

====Overview====

====Overview====

MIG welding may be the simplest welding method to use but that does not mean it is easy. First, it is important to wear the correct safety gear, i.e. closed shoes, pants, a welding coat, a welding helmet, and welding gloves, otherwise you will be burned by the UV light emitted by the welding arc. You must also make sue the machine is set up properly. To do this, the gas canister should be opened and regulator adjusted to 15 CFH. Depending on the material you are welding the voltage and wire feed speed will very; you can find what values these should be set to by referencing the chart inside the cover of the welder. Once the welder settings are correct, set up your work pieces using clamps and magnets to hold them in position and clipping the ground clamp to the work piece or the metal table as long as there is a clean contact between the table and the work piece. The most difficult piece is keeping the correct torch angle, keeping a consistent travel speed/pattern, and maintaining the correct distance from the work piece. If you have spent time on the welding simulator then the torch angle and travel speed/pattern should be simple to replicate. It is more difficult to visually reach the correct distance from the material but if the welder is making a nice sizzling (just like frying bacon) sound then it should be correct. If there is a lot of popping the the torch is too far away and if there is more of a bubbling sound then it is too close. After performing any welds make sure to reset the space by putting away any scrap metal and other debris.   

MIG welding may be the simplest welding method to use but that does not mean it is easy. First, it is important to wear the correct safety gear, i.e. closed shoes, pants, a welding coat, a welding helmet, and welding gloves, otherwise you will be burned by the UV light emitted by the welding arc. You must also make sue the machine is set up properly. To do this, the gas canister should be opened and regulator adjusted to 15 CFH. Depending on the material you are welding the voltage and wire feed speed will very; you can find what values these should be set to by referencing the chart inside the cover of the welder. Once the welder settings are correct, set up your work pieces using clamps and magnets to hold them in position and clipping the ground clamp to the work piece or the metal table as long as there is a clean contact between the table and the work piece. The most difficult piece is keeping the correct gun angle, keeping a consistent travel speed/pattern, and maintaining the correct distance from the work piece. If you have spent time on the welding simulator then the gun angle and travel speed/pattern should be simple to replicate. It is more difficult to visually reach the correct distance from the material but if the welder is making a nice sizzling (just like frying bacon) sound then it should be correct. If there is a lot of popping the the gun is too far away and if there is more of a bubbling sound then it is too close. After performing any welds make sure to reset the space by putting away any scrap metal and other debris.   

====Demonstration====

====Demonstration====

# Turn on the welder and adjust wire speed and voltage to match the parameters layed out by the welding chart. Refer to the image below to see the controls for doing this. [[File:MIG Controls.png|none|thumb|837x837px]]

# Turn on the welder and adjust wire speed and voltage to match the parameters layed out by the welding chart. Refer to the image below to see the controls for doing this. [[File:MIG Controls.png|none|thumb|837x837px]]

# Ensure you are wearing all necessary protective gear. This should include closed shoes, pants, a welding coat, a welding helmet, and welding gloves. There should be no skin exposed to the welding arc or it will cause burns.

# Ensure you are wearing all necessary protective gear. This should include closed shoes, pants, a welding coat, a welding helmet, and welding gloves. There should be no skin exposed to the welding arc or it will cause burns.

# Ensure the welding torch has proper amount of wire protruding from tip (about ¼ inch) and that the torch nozzle is clean of any debris. You can use pliers to scrape off any debris in the nozzle. If too long, trim excess with the welding pliers. If to short, pull the trigger while the torch is not in contact with anything and more wire will be fed out.

# Ensure the welding gun has proper amount of wire protruding from tip (about ¼ inch) and that the gun nozzle is clean of any debris. You can use pliers to scrape off any debris in the nozzle. If too long, trim excess with the welding pliers. If to short, pull the trigger while the gun is not in contact with anything and more wire will be fed out.

Perform a Weld:  

Perform a Weld:  

# Set up the work pieces in your desired configuration. Magnets and metal clamps are helpful for doing this and can be found on the tray below the tabletop.  

# Set up the work pieces in your desired configuration. Magnets and metal clamps are helpful for doing this and can be found on the tray below the tabletop.  

# Tack the pieces together in a few places by holding the torch at the proper angle and holding down the trigger for 2-3 seconds. Before pulling the trigger make sure to say "welding" to let everyone in the room know you are about to start. If you do not know the correct angle to hold the torch go practice some more on the [[Virtual Reality Welding Station]] until you are comfortable with the torch.  

# Tack the pieces together in a few places by holding the gun at the proper angle and holding down the trigger for 2-3 seconds. Before pulling the trigger make sure to say "welding" to let everyone in the room know you are about to start. If you do not know the correct angle to hold the gun go practice some more on the [[Virtual Reality Welding Station]] until you are comfortable with the gun.  

# Perform as many welds as needed. If you are doing everything right the noise should sound like sizzling bacon. Also, you may need to periodically trim the wire between welds to keep the correct distance from the work piece.  

# Perform as many welds as needed. If you are doing everything right the noise should sound like sizzling bacon. Also, you may need to periodically trim the wire between welds to keep the correct distance from the work piece.  

After Welding

After Welding

# Close gas cylinder valve.

# Close gas cylinder valve.

# Bleed any remaining gas by depressing trigger until regulator drops to 0. Make sure the torch is not in contact with anything while doing this.

# Bleed any remaining gas by depressing trigger until regulator drops to 0. Make sure the gun is not in contact with anything while doing this.

# Back out adjusting screw on regulator (Do Not unscrew all the way).

# Back out adjusting screw on regulator (Do Not unscrew all the way).

# Turn off the welder.

# Turn off the welder.

# Carefully coil the torch and return it to the welder. Make sure it does not get kinked.  

# Carefully coil the gun and return it to the welder. Make sure it does not get kinked.  

# Remove the ground clamp and clean up any scraps and slag from the work area.  

# Remove the ground clamp and clean up any scraps and slag from the work area.  

* Don’t unscrew valve adjusting screw all the way out. This could damage the valve.  

* Don’t unscrew valve adjusting screw all the way out. This could damage the valve.  

* Please avoid touching the hot metal surrounding the weld, even if you are wearing welding gloves. You could get burned and the heat may damage the gloves.  

* Please avoid touching the hot metal surrounding the weld, even if you are wearing welding gloves. You could get burned and the heat may damage the gloves.  

* Avoid stepping on or kinking the cable attached to the torch. This can interfere with the wire feeding system.  

* Avoid stepping on or kinking the cable attached to the gun. This can interfere with the wire feeding system.  

==Certification==

==Certification==

==Troubleshooting==

==Troubleshooting==

*  

*  

==Maintenance==

==Maintenance==

====General maintenance====

====General maintenance====