Miller Millermatic 212 Auto-Set Owner's Manual
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Miller Millermatic 212 Auto-Set Owner's Manual

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Millermatic 212
Auto-Set
OM-238118G
2019−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
™
File: MIG (GMAW)

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  • Page 1 OM-238118G 2019−05 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 212 Auto-Set ™ File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − GUIDELINES FOR MIG WELDING (GMAW) ........9-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Do Not Switch Wire Feed Output Duty Cycle While Welding Volts Increase Gas Metal Arc Wire Feed Spool Welding (GMAW) Gas Input Gas Output Rated No-Load Voltage Input Press To Reset...

  • Page 14: Welding Power Source Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-4. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.

  • Page 15: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 16: Weld Output Terminals And Selecting Cable Sizes

    A complete Parts List is available at www.MillerWelds.com 5-2. Weld Output Terminals And Selecting Cable Sizes NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft).

  • Page 17: Installing Work Cable And Clamp

    A complete Parts List is available at www.MillerWelds.com 5-4. Installing Work Cable And Clamp Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Tools Needed: 3/4 in.

  • Page 18: Setting Gun Polarity For Wire Type

    A complete Parts List is available at www.MillerWelds.com 5-6. Setting Gun Polarity For Wire Type Polarity Changeover Label Information Always read follow manufacture’s recommended Changing Polarity polarity. Wire Drive Work Clamp Lead Assembly Lead Positive Terminal Negative Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW).

  • Page 19: Connecting Spool Gun

    A complete Parts List is available at www.MillerWelds.com 5-7. Connecting Spool Gun A. Spoolmate 200 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel or if unit has a hole in the rear panel, gas hose can be routed through wire compartment.
  • Page 20 A complete Parts List is available at www.MillerWelds.com B. Spoolmatic 15A Or 30A Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel. Positive Weld Output Terminal Connect weld cable to weld output terminal.

  • Page 21: Installing Gas Supply

    A complete Parts List is available at www.MillerWelds.com 5-8. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Tools Needed: 1-1/8, 5/8 in. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.

  • Page 22: Installing Wire Spool And Adjusting Hub

    A complete Parts List is available at www.MillerWelds.com 5-9. Installing Wire Spool And Adjusting Hub Hand tighten knob clockwise. When a slight force is needed to turn spool, tension is set. To install either a 1 lb or 2 lb wire Installing 1 Or 2 lb Wire Spool spool, follow the procedure as shown in the illustration.

  • Page 23: Positioning Jumper Links

    A complete Parts List is available at www.MillerWelds.com 5-10. Positioning Jumper Links Check input voltage available at Tools Needed: site. 3/8 in. Jumper Links Access Door Open door. Jumper Link Label Check label − only one is on unit. 200 VOLTS 230 VOLTS Input Voltage Jumper Links Move jumper links to match input...

  • Page 24: Selecting A Location And Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-12. Selecting A Location And Connecting Input Power =GND/PE Earth Ground 230 VAC, 1 805 244-A Plug (NEMA Type 6-50P) Connect green or green/yellow grounding Installation must meet all National conductor to disconnect device grounding and Local Codes −...

  • Page 25: Threading Welding Wire

    A complete Parts List is available at www.MillerWelds.com 5-13. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling.

  • Page 26: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Controls Ref. 248 457-A Voltage Control Diagnostic Light the material thickness selected using the Voltage control (see Section 6-4). The Diagnostic light provides diagnostic Turn control clockwise inside white scale modes to help troubleshoot various Rotate Voltage control inside blue scale (22 (1-10) to increase voltage (see weld...

  • Page 27: Power Switch

    A complete Parts List is available at www.MillerWelds.com 6-2. Power Switch Power Switch Use switch to turn power on and off. Ref. 804908-A 6-3. Run-In Setting Run-In is the speed of the wire prior to the welding arc being struck. This setting is a percentage of the wire feed speed the unit is set to for welding. Programming values range from 25 −...

  • Page 28: Weld Parameter Chart

    A complete Parts List is available at www.MillerWelds.com 6-4. Weld Parameter Chart Auto-Sett - SIMPLE SETUP FOR WELDING MILD STEEL Example: .035” diameter wire, welding 16 ga. material. Activate Auto-Sett by selecting the diameter of the welding wire .030” Auto-Set* with the WIRE SPEED knob.
  • Page 29 A complete Parts List is available at www.MillerWelds.com Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. 1. Number on right of slash is Wire Speed Knob Setting. (Example: 4 / 65) M A T ER I A L T H 14 ga...

  • Page 30: Section 7 − Maintenance &Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels...

  • Page 31: Aligning Drive Rolls And Wire Guide

    A complete Parts List is available at www.MillerWelds.com 7-4. Aligning Drive Rolls and Wire Guide Turn Off power. View is from top of drive rolls looking down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw...

  • Page 32: Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 7-6. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 5-12). Check and replace power switch if necessary. Replace building line fuse or reset circuit breaker if open (see Section 5-12). Secure gun plug in receptacle or repair leads, or replace trigger switch (see welding gun Owner’s Manual).
  • Page 33 Notes OM-238118 Page 29...

  • Page 34: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Welding Power Source Circuit Diagram OM-238118 Page 30...
  • Page 35 248494-A OM-238118 Page 31...

  • Page 36: Section 9 − Guidelines For Mig Welding (Gmaw)

    SECTION 9 − GUIDELINES FOR MIG WELDING (GMAW) 9-1. Typical GMAW (MIG) Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...

  • Page 37: Holding And Positioning Welding Gun

    9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam.

  • Page 38: Gun Movement During Welding

    9-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 39: Troubleshooting − Excessive Spatter

    9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Remedy Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 40: Troubleshooting − Lack Of Penetration

    9-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Remedy Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

  • Page 41: Troubleshooting − Waviness Of Bead

    9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Remedy Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand.

  • Page 42: Common Gmaw (Mig) Shielding Gases

    9-16. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Short Short...
  • Page 43 Problem Probable Cause Remedy Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder. Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line.

  • Page 44: Section 10 − Parts List

    SECTION 10 − PARTS LIST 10-1. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire (solid steel and metal cored). U-Grooved rolls for soft and soft shelled cored wires (aluminum). U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2019 (Equipment with a serial number preface of MK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Subarc Wire Drive Assemblies below, Miller Electric Mfg.
  • Page 48 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2019 Miller Electric Mfg. LLC 2019−01...

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