Miller Millermatic 212 Auto-Set Owner's Manual
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Summary of Contents for Miller Millermatic 212 Auto-Set
- Page 1 OM-238 118D 2010−04 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 212 Auto-Set ™ File: MIG (GMAW) Visit our website at 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES ..........8-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,... - Page 14 OM-238 118 Page 10...
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Page 15: 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 16: Welding Power Source Duty Cycle And Overheating
A complete Parts List is available at www.MillerWelds.com 4-2. 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 17: Connecting To Weld Output Terminals
A complete Parts List is available at www.MillerWelds.com 4-4. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) 803 778-A Correct Installation Incorrect Installation Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper... -
Page 18: Installing Welding Gun
A complete Parts List is available at www.MillerWelds.com 4-6. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. -
Page 19: Connecting Spool Gun
A complete Parts List is available at www.MillerWelds.com 4-8. 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.
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Page 21: Installing Gas Supply
A complete Parts List is available at www.MillerWelds.com 4-9. 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 Mig Wire Spool And Adjusting Hub Tension
A complete Parts List is available at www.MillerWelds.com 4-10. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring When a slight force is needed with 8 in. (200 mm) spools. 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 Spindle... -
Page 23: Positioning Jumper Links
A complete Parts List is available at www.MillerWelds.com 4-11. 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 4-13. Selecting A Location And Connecting Input Power 18 in. (457 mm) of Do not move or operate unit space for airflow where it could tip. =GND/PE Earth Ground 230 VAC, 1 805 244-A Plug (NEMA Type 6-50P) Disconnect Device Line Terminals... -
Page 25: Threading Welding Wire
A complete Parts List is available at www.MillerWelds.com 4-14. 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 5 − Operation
A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls M A T E RIA L T H I C 14 ga E SP E E D V O L TA G E W I R 16 ga 1/8”... - Page 27 A complete Parts List is available at www.MillerWelds.com Notes OM-238 118 Page 23...
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Page 28: Weld Parameter Chart
A complete Parts List is available at www.MillerWelds.com 5-2. 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...
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Page 30: Section 6 − Maintenance &Troubleshooting
A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. 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 6-4. 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 A complete Parts List is available at www.MillerWelds.com Wire Drive/Gun Trouble Remedy Wire feeding stops during welding. Straighten gun cable and/or replace damaged parts (see welding gun Owner’s Manual). Adjust drive roll pressure (see Section 4-14). Readjust hub tension (see Section 4-10). Replace contact tip if blocked (see welding gun Owner’s Manual).
- Page 33 Notes OM-238 118 Page 29...
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Page 34: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Welding Power Source Circuit Diagram OM-238 118 Page 30... - Page 35 238 117-D OM-238 118 Page 31...
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Page 36: Section 8 − Mig Welding (Gmaw) Guidelines
SECTION 8 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 8-1. Typical 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: Typical Mig Process Control Settings
8-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) -
Page 38: Holding And Positioning Welding Gun
8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece... -
Page 39: Conditions That Affect Weld Bead Shape
8-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long... -
Page 40: Gun Movement During Welding
8-5. 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 41: Troubleshooting − Excessive Spatter
8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 42: Troubleshooting − Lack Of Penetration
8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions 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 43: Troubleshooting − Waviness Of Bead
8-14. 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 Corrective Actions 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 44: Common Mig Shielding Gases
8-16. Common 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. - Page 45 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. 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 Readjust welding parameters.
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Page 46: Drive Roll And Wire Guide Kits
SECTION 9 − PARTS LIST 9-1. 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 47 Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
- 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 2010 Miller Electric Mfg. Co. 2010−01...
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