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  1. #1
    Join Date
    Mar 2011
    Posts
    8

    Default Problem with Miller 211...since it was new

    Hey guys, I purchased a Miller 211 maybe 2 years back and have been using it for a lot of race car projects as well as my own street rod. The welds I get from it WORK, but they are just not as 'pretty' as what I have come to expect from Miller and the machine doesn't make it easy either.

    Just a little background, I have only been welding for a few years but 4 of those have been professionally for a speed shop and I became the head fabricator/welder for the last year I was there. As far as experience goes, I have layed thousands of beads on the Miller 175 and Miller 212's my shop had. The 212 had an aftermarket ground and tweco torch but the 175 was stock. Both made awesome welds every time and weren't very touchy. I'd get nice welds even when on my back welding roll cages through dashboards and what not, the machines (especially the 212) seemed to be very forgiving both with torch angle/distance and settings.

    Anyway, ever since I bought my 211 for home use I have noticed that it just doesn't weld as nice as the other machines I have used. It's hard to put to words, but the sound isn't right, it seems as though it requires excessive wire speed to get the sound right and then the welds come out kind of sloppy/gloppy. It also spits more than I am used to. Overall, it almost acts as if a welder would when using compromised wire, but I have swapped wire out multiple times with various brands and it made no difference.

    I mean I am getting structurally sound welds but they just aren't as easy to make or as clean as I am used to getting and they look less defined, rougher and gloppier (as one would expect with excessive wire speed).

    For my electric source I have a stand alone 220 that a professional electrician installed specifically for this welder. Even tried the welder on my shops electric and it made no difference. I have been through probably 4 tanks of gas so it's not a bad mix. Swapped contact tips, checked bolts on the ground etc... Everyone keeps telling me to try a new liner, but this problem has happened since new, why would the liner be bad? I suppose it could have been damaged or something from the start.

    The other strange thing i notice is that when you first pull the trigger, the wire feed starts off slow then speeds up after maybe a second. I don't know if this is part of the 'smooth start' feature but I know it has done it since new and I have never used another Miller (or Lincoln) machine that did this.

    Any help is appreciated! I'll be welding control arms up for my own car in a few days and I was really hoping to fix this problem and get some real nice looking welds! Thanks in advance
    Last edited by kris396ss; 11-19-2013 at 09:43 AM.

  2. #2
    Join Date
    Nov 2003
    Posts
    3,051

    Question

    Could you post some pics of these less than ideal welds??

    might help us diagnose the prob...

    It could be something as simple as a bad or poorly connected filter capacitor...

    goofing up "Eli the Ice man"..(Reactance)...... and changing the arc/bead characteristics....

    Or..??? who knows..

    But pics could not hurt...
    Last edited by H80N; 11-19-2013 at 12:38 PM.
    .

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  3. #3
    Join Date
    Sep 2009
    Location
    South Carolina
    Posts
    570

    Default

    The wire starting slow then speeding up is called soft start I think. Anyway it is supposed to do that on the 211.

    I notice pops and spits from my 211 also. usually I blame it on stick out and short 1" welds. I always get good results on 220v and thicker metal. 1/16" thick stop and start short welds = some great and some popping.

    Cut the wire right on starts and ground it good.

    It seems to like a little weave or half circle even when doing short small welds. Also the auto set is a little hot for myself.

  4. #4
    Join Date
    Dec 2007
    Location
    Los Angeles
    Posts
    2,837

    Default

    I've never liked mine either.
    Ed Conley
    http://www.screamingbroccoli.net/
    MM252
    MM211
    Passport Plus w/Spool Gun
    TA185
    Miller 125c Plasma 120v
    O/A set
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    You can call me Bacchus

  5. #5
    Join Date
    Nov 2013
    Location
    Toronto
    Posts
    46

    Default Problem with Miller 211...since it was new

    Mine welds great except for the couple times I have the settings for the wrong voltage as I go from 220 to 120 quite a bit. But it is kinda easy to over look so maybe double check that

  6. #6
    Join Date
    Sep 2005
    Location
    Salem ,Ohio
    Posts
    3,898

    Cool

    What size wire are you using? and gas kind?...Bob
    Bob Wright, Grandson of Tee Nee Boat Trailer Founder
    Metal Master Fab Salem, Oh 44460
    Birthplace of the Silver & Deming Drill
    1999 MM185 w/185 Spoolgun,1986 Thunderbolt AC/DC
    Spool Gun conversion. How To Do It. Below.
    http://www.millerwelds.com/resources...php?albumid=48

  7. #7
    Join Date
    Oct 2006
    Location
    Illinois
    Posts
    596

    Default

    Are you using auto set ?? Auto set seems to run hot.
    A better ground clamp may help . What wire ? I found that the 211 runs better on .030 wire . My personal favorite is Lincoln L-56. What gas ?

  8. #8
    Join Date
    Oct 2004
    Location
    Edmonton, Alberta
    Posts
    7,617

    Default

    If you still have a factory ground clamp, best to change it to a better brass version. Problems should dissapear

  9. #9
    Join Date
    Mar 2012
    Location
    Brookshire, Texas
    Posts
    21

    Default

    You should also check that your machine is set to run with the 220 power you have, there are little brass tabs on the inside by the spool of wire, sometimes the machines are shipped set for 520 instead of 220

  10. #10
    Join Date
    Oct 2004
    Location
    Edmonton, Alberta
    Posts
    7,617

    Default

    Quote Originally Posted by S.A.W View Post
    You should also check that your machine is set to run with the 220 power you have, there are little brass tabs on the inside by the spool of wire, sometimes the machines are shipped set for 520 instead of 220

    Huh whats 520?, these machines only work on 230 and 120, there is no 460 or 575

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