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Thread: I need a little help on the Millermatic 200

  1. #1
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    I need a little help on the Millermatic 200

    About 3 years ago I went through this machine and it's been working fine up until 2 days ago.

    About a week ago I started another project and did a lot of welding. Everything went well the welder was working great the welds looked good and the fan would come on after a couple minutes of welding.

    Then two days ago I went to use the welder and I noticed it was buzzing a little louder almost a growling buzz that you could almost feel up in the gun when ever you were welding. The fan comes on and everything seems to work fine except the weld bead is running a little cold. the edges of the bead seems like you could pop the bead off of the metal with a screw driver.

    I never changed the settings and I'm welding 1/4" and 3/8" steel. The settings are position1 high, 50 wire speed 20cfh on the 75/25 gas.

    I don't know if I have anything to worry about. but it just seems weird that I noticed the louder buzzing and different way it was welding.
    any help would be appreciated, thanks.

    Here's a weld from a month ago


    From about a week ago when I did a lot of welding


    From 2 days ago. I used the same method, speed and settings as in the other two photos.

  2. #2
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    Re: I need a little help on the Millermatic 200

    Hi Doug.
    Not familiar with that machine, but I would check the simple things first.
    1. Good ground, ground clamp lead tight at both ends.
    2. MIG gun fully seated - it will disengage slightly if pulled by gun and hard to be sure fully seated. Loosen, remove, re-insert and tighten.
    3. Power lead snug to the stud.

    Good luck. It is more likely something simple.
    Burt
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  3. #3
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    Re: I need a little help on the Millermatic 200

    The contactor is probably shot Doug. Pretty common on these types of machines. When the contacts get worn, power cannot fully transfer through it. As power is transferring thru the contacts, the lack of good connection is what causes the buzzing. Sometimes other components inside them come loose and cause excessive noise, but most of the time poor output and loud noise coming from the machine is a classic case of contactor failure/need of service.

    I believe it's a two pole, 30 or 40 amp job, with a 24 VAC coil. You can buy a replacement almost anywhere online. I buy them from an HVAC company on eBay for the Maxtrons and they're under $20/ea. You don't need to buy an expensive one IIRC, it's a two pole job, but even a three pole one would work. As long as the configuration is similar and coil voltage is the same, you're good to go.

    That's almost a certainty what the issue is. You can even take it apart and dress the contact points to get you by for the time being. It's the component that looks like a big open relay with larger wires running to and from it. And as Burt said, check the pin connections and make sure they're not heavily pitted or damaged. The sockets can wear out over time too. Try changing settings to confirm it, but I'm thinking the contactor is the problem here. Gotta run.

    Good luck with it.
    Last edited by 7A749; 09-16-2016 at 07:01 AM.

  4. #4
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    Re: I need a little help on the Millermatic 200

    Definitely check the contacts. I had to replace the contactor on my MM210 because they were severely damaged. I have a thread on here somewhere. But it was cheap ~ $25.

    Also make sure the female panel / jack plug connectors are still tight as well as wire connections.
    "You can't out puke a buzzard"

  5. #5
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    Re: I need a little help on the Millermatic 200

    Quote Originally Posted by wb4rt View Post
    Hi Doug.
    Not familiar with that machine, but I would check the simple things first.
    1. Good ground, ground clamp lead tight at both ends.
    2. MIG gun fully seated - it will disengage slightly if pulled by gun and hard to be sure fully seated. Loosen, remove, re-insert and tighten.
    3. Power lead snug to the stud.

    Good luck. It is more likely something simple.
    Hey Burt,
    Thanks for the suggestions. This Millermatic was gone through about 3 years ago, all female (yellow) connectors were replaced and it had a brand new M25 gun on it. I feel that all external connections are good.


    Quote Originally Posted by 7A749 View Post
    The contactor is probably shot Doug. Pretty common on these types of machines. When the contacts get worn, power cannot fully transfer through it. As power is transferring thru the contacts, the lack of good connection is what causes the buzzing. Sometimes other components inside them come loose and cause excessive noise, but most of the time poor output and loud noise coming from the machine is a classic case of contactor failure/need of service.

    I believe it's a two pole, 30 or 40 amp job, with a 24 VAC coil. You can buy a replacement almost anywhere online. I buy them from an HVAC company on eBay for the Maxtrons and they're under $20/ea. You don't need to buy an expensive one IIRC, it's a two pole job, but even a three pole one would work. As long as the configuration is similar and coil voltage is the same, you're good to go.

    That's almost a certainty what the issue is. You can even take it apart and dress the contact points to get you by for the time being. It's the component that looks like a big open relay with larger wires running to and from it. And as Burt said, check the pin connections and make sure they're not heavily pitted or damaged. The sockets can wear out over time too. Try changing settings to confirm it, but I'm thinking the contactor is the problem here. Gotta run.

    Good luck with it.
    Hey Steve,
    Thanks for your response.
    I'll have a look at the contactor. Just to double check, it's what's in the red circle? this one looks to be 3 pole.

    I did run it through some different settings. I went up on the selector to #2 and #3. I also set the wire speed up to 60.


    Quote Originally Posted by Pipeliner View Post
    Definitely check the contacts. I had to replace the contactor on my MM210 because they were severely damaged. I have a thread on here somewhere. But it was cheap ~ $25.

    Also make sure the female panel / jack plug connectors are still tight as well as wire connections.
    Hey Pipeliner,
    Thanks for your suggestions. I'm going top check out the contactor.
    Last edited by Doug_; 09-16-2016 at 02:45 PM.

  6. #6
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    Re: I need a little help on the Millermatic 200

    Quote Originally Posted by Doug_ View Post
    Just to double check, it's what's in the red circle?
    Yes, that's it. Here's a link to what mine looked like:

    http://weldingweb.com/vbb/showthread.php...t-all-the-time
    "You can't out puke a buzzard"

  7. #7
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    Re: I need a little help on the Millermatic 200

    I was able to pull the contact points out of mine and clean them up. Made a huge difference. I also took the opportunity to clean all the contacts on the selector, as well as the cable connections. The back side of one of the din plugs is notorious on the machines for having arcing problems. Unbolt and wire brush and retighten.

  8. #8
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    Re: I need a little help on the Millermatic 200

    Quote Originally Posted by Pipeliner View Post
    Yes, that's it. Here's a link to what mine looked like:

    http://weldingweb.com/vbb/showthread.php...t-all-the-time
    Pipeliner, Thanks, I got it pulled out over the week end.

    Quote Originally Posted by walker View Post
    I was able to pull the contact points out of mine and clean them up. Made a huge difference. I also took the opportunity to clean all the contacts on the selector, as well as the cable connections. The back side of one of the din plugs is notorious on the machines for having arcing problems. Unbolt and wire brush and retighten.
    Walker, After pulling and inspecting mine. I could probably clean it up bit I think I'll get a new one, clean and save the old one as a backup.


    Steve,
    I got the Contactor out and to my surprise it's a 110/120 volt coil. According to Furnas this is a 60 amp contactor.






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