Miller Electric Millermatic 212 Auto-Set Owner'S Manual Download Page 1

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Processes

Description

Arc Welding Power Source
and Wire Feeder

OM-238 118F

2012

−

Visit our website at

www.MillerWelds.com

Millermatic 212

Auto-Set

Flux Cored (FCAW) Welding

MIG (GMAW) Welding

File: MIG (GMAW)

™

Summary of Contents for Millermatic 212 Auto-Set

Page 1: ...cesses Description Arc Welding Power Source and Wire Feeder OM 238 118F 2012 01 Visit our website at www MillerWelds com Millermatic 212 Auto Set R Flux Cored FCAW Welding MIG GMAW Welding File MIG GM...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...Power Source Duty Cycle And Overheating 12 4 3 Volt Ampere Curves 12 4 4 Weld Output Terminals And Selecting Cable Sizes 13 4 5 Connecting To Weld Output Terminals 14 4 6 Installing Work Cable And Cla...

Page 4: ...ics 38 8 7 Good Weld Bead Characteristics 38 8 8 Troubleshooting Excessive Spatter 39 8 9 Troubleshooting Porosity 39 8 10 Troubleshooting Excessive Penetration 39 8 11 Troubleshooting Lack Of Penetra...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eq...

Page 6: ...ums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoli...

Page 7: ...NG PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards...

Page 8: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Healt...

Page 9: ...utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les con...

Page 10: ...ne et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur...

Page 11: ...eur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprim...

Page 12: ...der seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion D L utilisateur est tenu de faire corriger rapidement par un lectricien quali...

Page 13: ...t Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Re...

Page 14: ...OM 238 118 Page 10...

Page 15: ...utput Amperage Range DC Max Open Circuit Voltage DC Amps Input at Rated Output 60 Hz Single Phase 200 208 V 230 V KVA KW 160 A at 24 5 VDC 60 Duty Cycle 210 A at 22 VDC 30 Duty Cycle 30 210 34 5 31 1...

Page 16: ...es for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 9...

Page 17: ...ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Welding Amperes 10 60 Duty Cycle AWG mm2 60 100 Duty Cycle AWG mm2 10 100 Duty Cycle AWG mm2 Ref 805 243 A Positive Negative 100 4 20 4 20 4 20 3 30 2 35...

Page 18: ...e terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the sur...

Page 19: ...ed collar Close door 805 424 A 4 3 1 2 4 8 Setting Gun Polarity For Wire Type 1 Polarity Changeover Label Information Always read and follow manufacture s recommended polarity 1 3 4 11 16 in Ref 190 8...

Page 20: ...panel gas hose can be routed through wire compartment 4 Positive Weld Output Terminal Connect weld cable to weld output terminal 5 Regulator Flowmeter Route shielding gas hose up to regulator flowmete...

Page 21: ...sitive Weld Output Terminal Connect weld cable to weld output terminal 5 Regulator Flowmeter Route shielding gas hose up to regulator flowmeter Connect gas hose to fitting on regulator flowme ter Two...

Page 22: ...Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator fl...

Page 23: ...nsion is set 15 16 in Use compression spring with 8 in 200 mm spools Tools Needed 805 253 A Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the procedure as shown in...

Page 24: ...Output 31 28 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 35 30 Normal Operating Fuses 3 45 40 Min Input Conductor Size In AWG 4 10 10 Max Recommended Input Conductor Length I...

Page 25: ...input power 2 Plug NEMA Type 6 50P 3 Receptacle NEMA Type 6 50R Customer Supplied 4 Input Power Cord Connect directly to line disconnect device if hard wiring is required 5 Black And White Input Condu...

Page 26: ...mbly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trig...

Page 27: ...des diagnostic modes to help troubleshoot various malfunctions with the unit see Section 6 5 4 Auto Set Light To use Auto Set mode rotate Wire Speed control inside blue area for the applicable Weld Wi...

Page 28: ...Run Ins are set to 50 from the factory for optimal arc starts To adjust run in first turn off the unit While the unit is off pull the trigger on the gun that is going to be adjusted then turn on the...

Page 29: ...A complete Parts List is available at www MillerWelds com OM 238 118 Page 25 Notes...

Page 30: ...with the WIRE SPEED knob Auto Sett light comes on Example 035 diameter wire welding 16 ga material Select thickness of the mild steel being welded with the VOLTAGE knob Setup complete Auto Sett SIMPLE...

Page 31: ...7 5 5 6 5 4 5 3 4 3 5 4 5 7 8 6 9 7 6 5 3 4 2 3 5 4 8 8 5 9 7 8 8 5 6 5 7 5 3 5 5 3 5 6 7 5 MAX 6 5 8 5 3 6 5 3 5 7 3 5 35 4 40 5 5 45 4 60 3 5 50 2 5 32 3 40 4 5 65 5 50 4 40 3 30 6 55 Manual Setup...

Page 32: ...p saver short circuit protection extends contact tip life and protects internal components from damage If contact tip is shorted to workpiece the unit shuts down the welding output but the fan continu...

Page 33: ...Release trigger and let unit cool before continuing welding operation Flashing 1 Time Trigger Error Gun trigger is closed or shorted when unit power is turned on Release trigger then pull trigger agai...

Page 34: ...Over Temp light on Unit has overheated and output stops Let unit cool before continuing welding operation Over Temp light blinks rapidly Gun trigger is closed or shorted when unit power is turned on O...

Page 35: ...OM 238 118 Page 31 Notes...

Page 36: ...OM 238 118 Page 32 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Welding Power Source Circuit Diagram...

Page 37: ...OM 238 118 Page 33 248 494 A...

Page 38: ...er Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp 8 1 Typical MIG Process Connections Weld current can damage electronic parts in vehicles Disconnect both battery cables before...

Page 39: ...arameters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 03...

Page 40: ...in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle...

Page 41: ...electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WE...

Page 42: ...t Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slig...

Page 43: ...in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove s...

Page 44: ...welding power source 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actio...

Page 45: ...upport hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Page 46: ...f damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on...

Page 47: ...ecessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameter...

Page 48: ...ires flux cored 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Ref S 0026 B 7 91 Wire Diameter Fraction Decimal Metric 030 035 in...

Page 49: ...Notes...

Page 50: ...Notes...

Page 51: ...ontrols and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils...

Page 52: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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Miller Electric Millermatic 212 Auto-Set, Owner'S Manual

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