211 millermatic issues

[Itsme7]

Hey everyone. I purchased a 211 in march of 2010. Hasnt seen much use since, just little projects here and there (havent even used up a full spool of wire yet) Today i was doing some welding, using 110v, welding some 14 gage sheet metal, and the machine stopped feeding. It welds, but it wont feed wire. I tried playing with the plug for the gun, wire tension, ect, and still nothing. It welds and is feeding the shielding gas, just seems like the feed motor died on me? Doesnt even make a noise when pulling the trigger. Any ideas of what this could be? Tomorrow im heading to the local welding store that also services welders, just wanted to see if anyone had thoughts on what it could be. Thanks again.

[Diverdude]

check the spool gun switch on the front.

[Itsme7]

I checked and low and behold, you were right... i feel like such a idiot lol. Thanks for that, saved me the embarrassment of someone making me feel like a ass in person lol.

[Sberry]

Send the man 20$,,, ha

[Diverdude]

it happens sometimes, glad to help

[Danny]

I did the same thing once on a Hobart Handler 210. It took me close to 30 minutes to figure out what was wrong with the unit. I had my mutlimeter with me as was ready to take the wrapper off the unit to do some troubleshooting when I noticed the little spoolgun icon near the socket for the gun control wires. This triggered an idea so I took a look at the rocker switch in the wire drive compartment, and sure enough when I installed the roll of wire onto the unit I more then likely bumped the switch into the spoolgun position.

[eecervantes83]

I wish they would have reversed the power switch location with the spoolgun switch, power in the front and spoolgun in the rear.

I'd go further than that - I think the spoolgun switch shouldn't even exist - the machine should auto-detect when the spoolgun is connected, and react appropriately. It would take a couple of extra components on the PC board to detect the current flowing (or not) to the drive motor via the small connector, or maybe even NO changes on the PC board to wire the gun drive motor to deactivate the power supply drive motor.

As to the power switch: I've already gotten fed up with that. I was borrowing a Lincoln with a front switch before I bought this 211, so that was a big shock to find the Miller switch on the back. I moved it last night...



I have a few other ideas for internal mods that I'll work on later: hanging multiple spools in the case, connecting BOTH gas bottles & auto-selecting them...

Like what you did. I might follow.

[Steve83]

I used a Brother P-Touch with white-on-clear ES adhesive to add "ON - OFF" labels beside the switch in a font similar to the welder's original, so now it almost looks factory.

[Thrutraffic]

Thanks Steve83. I'll be moving that switch this weekend too. It's annoying back there.

And you are correct. The sensing components for the spool gun would cost less that the switch gear.

[cruizer]

Your welcome to do what ever you want to, however, if it was still on warranty, it isn't now.....