cleaning out my Millermatic 211 and drive motor replacement
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  1. #1
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    cleaning out my Millermatic 211 and drive motor replacement

    So I finally took my Millermatic 211's cover off so I could clean it after two years. Definitely needed a dusting.



    I was surprised to see the size of the small fan that is responsible for the cooling of the unit! Maybe if Miller had put in at least a 4" fan it would have a better duty cycle. Oh well, it doesn't bother me as I have never had the need to set it to kill for more than a minute or so.



    so this is the sucker that is wobbling on me. Ended up finding a replacement for $60. Gonna swap it out when it gets here.
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  2. #2
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Im certainly a DIY guy but I'd take that sucker in for service.Those guys are in 8 hours a day. They can spot stuff you cant even fathom.Like the Milwaukee(junk) repair guys. They know what the problem is before I unbag it.

  3. #3
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    I did. I had to pay a Miller service center 2 hours away $50 just for them to tell me to tighten down the pressure knob to 4.
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  4. #4
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by Oscar View Post
    I did. I had to pay a Miller service center 2 hours away $50 just for them to tell me to tighten down the pressure knob to 4.
    My condolences. That's a fuggin shame.

  5. #5
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Thought they had a 3 year warranty have they been out that long

  6. #6
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    When the Miller repair reps told him to tighten down to 4 they basically told him there was no problem with his machine. That sucks... That was one of my biggest problems with the miller 211 when I was looking for a new mig machine. Lincoln MP210 had the same issues iirc.
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  7. #7
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Oscar I'd presume that if there is that much junk inside the machine that means the fan is pushing some air. Looks like saw dust to me...
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  8. #8
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Nah, it's not sawdust, that's just from me using it/leaving it outdoors for 2 years. It's just regular dust as I don't do any woodworking anywhere near this machine. It does work just fine, I just don't like having to tighten it down so much because I know if it was running true, it would grip the wire just fine set to ~2.5 like the manual suggests; in fact at that setting it grips the wire just fine on the high part of the wobble, and slips on the low part, with a mild curve of the mig gun, which is how it is in a regular situation---it's never perfectly straight in the real world. Even though it's two years old, I've only ran maybe 50-60 lbs of wire total, give or take. Some have been 10lb spools and some were 4" spools, so I lost track because I use it sparingly. In contrast, the Miller 211 that we bought at my work has no such wobble and runs much much truer with no slipping at the suggested tension setting.

    If the new replacement motor assembly isn't any better, no big deal since the machine itself as a whole hasn't skipped a beat since I've owned it. It can handle pretty much anything I would need it for as a hobbyist, and I think I want an HTP ProPulse200 too.
    Last edited by Oscar; 11-07-2017 at 11:06 PM.
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  9. #9
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Not much of a warranty if you had to pay 50 bucks

  10. #10
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by Oscar View Post
    Nah, it's not sawdust, that's just from me using it/leaving it outdoors for 2 years. It's just regular dust
    Awe poor little machine... I'd at least give it a sweater for cold damp winter weather.
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  11. #11
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by N2 Welding View Post
    I'd at least give it a sweater for cold damp winter weather.
    You don't know Laredo, Tx. Aside from Death Valley, we usually get the first 100°F day of the calendar year in the whole USA, and the most during the year too, LOL.
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  12. #12
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Never looked it up before now. Makes sense you are practically in Mexico.
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  13. #13
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Is the fan ducted to or from the outside, or is it able to recirculate some of the heated air within the unit? It makes a difference and maybe a big difference depending on the config. It doesn’t look all that dirty. I’ve seen confusers that we’re clogged with dust bunny’s and overheating because of it.

  14. #14
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    You want to see a machine with a duty cycle that has it shutting itself off after not much work, try an MM175 (which also has the bleeping Auto Set). I had a Century 150A MIG machine, yeah a Century, the machine all supposedly knowledgable welders scorn, yet it would outwork that MM175 day after day AND it had no goofy automatic heat/WFS adjustments to make your choices for you. I sold the Century when I had a chance to buy the MM175 new at a good discount. Figured "Hey, a Miller ought to be better than a Century." Well, not that model, for sure!!

    I have thought about making a shroud around the fan in the MM175, a ducted fan being a better air mover than an unducted fan. But I'm told that the transformer will only shed heat so fast, and that more airflow probably wouldn't help much or at all.

    I have also wondered why the cooling air intakes on welding machines can't have good automotive-style air filters in front of them. There are lots of car air filters that will pass way more air than a welder fan pulls, and you can get replacement filter elements cheap. A Miller rep told me, "We tried a filter on one machine but it was too restrictive." Well, bull!! Let an automotive engineer design it if you can't do it. Yes, the owners would have to change filter elements occasionally. But they wouldn't need to blow the crud out of their machines as often. And if they utilized a K&N automotive air filter, the best air filter you can buy, you just wash it out and re-treat it, then put it back in.

    Grump, grump, grump.
    Last edited by old jupiter; 11-08-2017 at 01:59 PM.

  15. #15
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    The fan is the entrance to the "wind tunnel", which is the black box that the main board is attached to. The air is pulled in from the front, and once it enters the wind tunnel, it can only exit out the back. I checked it with the cover off.

    What would be really cool is to use the fan-on-demand feature with a duct and a carbon trap/filter/mesh/etc to serve as the fume extractor as well! Pull the trigger, and the machine cools itself while filtering out the welding fumes at the same time!
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  16. #16
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Yeah, I can see your fan is set up a lot different from the one in my MM175.

  17. #17
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by N2 Welding View Post
    Awe poor little machine... I'd at least give it a sweater for cold damp winter weather.
    better late than never!

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  18. #18
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    All better now.
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  19. #19
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Brand new drive motor assembly installed. Two different drive wheels. I guess that's just how they are. Oh well, I mean it still works, just have to tighten down to about 3.5ish.



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  20. #20
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Well that sux, now you have a motor you don't need ???
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  21. #21
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    I have the same 211 and have a small wobble as well. Is the wobble from the motor shaft or the drive wheel or both? I did notice how the fit of the drive wheel to the shaft is not very precise.

  22. #22
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    I guess you can say I have a spare motor.

    the shaft itself is driven by a set of gears within the drive motor assembly. I haven't set my dial indicator on it yet, but even without doing so, the wobble is visible on the shaft itself with no wire drive roll installed.
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  23. #23
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by Oscar View Post
    Brand new drive motor assembly installed. Two different drive wheels. I guess that's just how they are. Oh well, I mean it still works, just have to tighten down to about 3.5ish.



    Did you try the three groove drive roll on the new drive assembly.

    Is the wire guide on the power pin end of you gun lead making light contact with the drive roll? When I tried my HTP M -25 gun on my Multimatic 215, I couldn't full seat the gun because the wire guide would make contact with the drive roll.
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  24. #24
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Yeah,

    Take a video clip when the tensioner is down and feeding wire.

    I'll bet that takes some of the slop out of the drive shaft on its bearing
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  25. #25
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    Re: cleaning out my Millermatic 211 and drive motor replacement

    Quote Originally Posted by C. Livingstone View Post
    Yeah,

    Take a video clip when the tensioner is down and feeding wire.

    I'll bet that takes some of the slop out of the drive shaft on its bearing
    Not necessary, as my visual inspection of the issue while actually feeding wire is what prompted me to look into this. The drive roll [as it wobbles] will literally make the upper guide wheel and tensioner bob up-and-down. There is no slack to take-up, as even cranking it down to 4 does not "solve" the wobble, at all.

    Quote Originally Posted by Dan View Post
    Did you try the three groove drive roll on the new drive assembly.

    Is the wire guide on the power pin end of you gun lead making light contact with the drive roll? When I tried my HTP M -25 gun on my Multimatic 215, I couldn't full seat the gun because the wire guide would make contact with the drive roll.
    Yes, that is the first video. New drive motor assembly with the stock 3-groove drive roll.

    No it is not making contact. It is very very close, I checked. Definitely can't tell from the video though.
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