Miller Electric Millermatic 212 Users Manual A DC12 46 MM
Millermatic 212 to the manual ced8cd8e-7882-caa4-0dd0-557197d6c608
2015-02-02
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Millermatic 212 Issued August 2007 • Index No. DC/12.46 ® Quick Specs Industrial Applications Processes Light Fabrication Garages/Body Shops Farm/Ranch Vocational/Technical Schools MIG (GMAW) Flux Cored (FCAW) Input Power 200(208)/230 V MIG Arc Welding Power Source Rated Output 160 A at 24.5 VDC, 60% Duty Cycle Max. Open-Circuit Voltage 34.5 VDC Amperage Range 30 – 210 A Wire Feed Speed 50 – 700 IPM (1.3 – 17.8 m/min) Weight 190 lb (86 kg) The Power of Blue . ® Comes Complete With: 7 ft (2.1 m) power cord and plug NEW! 15 ft (4.6 m), 250 amp M-25 MIG gun for .030/.035 in wire 10 ft (3 m) work cable and clamp Argon mix regulator/flow gauge and hose Extra contact tips NEW! Factory-installed running gear with EZ-Change™ Low Cylinder Rack .030/.035 in reversible drive rolls NEW! Set-up and operation interactive CD Seven taps provide wider welding range of 30 – 210 amps with improved high and low ends to weld materials from 22 gauge up to 3/8 in (9.5 mm) thick in a single pass. NEW! Angled, dual-gear driven, cast aluminum drive system features no-tool, quick-change reversible drive rolls and an easy-to-set, scaled tension knob. See page 3 for more information. NEW! Patent-pending EZ-Change™ Low Cylinder Rack allows operators to easily roll cylinders on and off of rack — no need to lift cylinders. See page 3 for more information. NEW! EZ-Access™ Consumable Compartment and Parameter Chart — set weld parameters right the first time with convenient new flip-down compartment that provides fast access to parameter chart and consumables. See page 3 for more information. Add the Spoolmate™ 3035 spool gun for aluminum welding. Easy to install with direct hook up. And with Miller’s exclusive Gun-On-Demand,™ simply pull the trigger for either gun and you’re ready to weld. No time wasted toggling switches! NEW! Larger work area — now with longer 15-ft M-25 gun. NEW! Thermal overload protection shuts down unit and activates over temperature light if airflow is blocked or duty cycle is exceeded. Automatically resets when fault is corrected and unit cools. Less weld cleanup with Active Arc Stabilizer ™ — patented Miller design provides excellent starts proven superior to the competition. Welder is warranted for 3 years, parts and labor. Original main power rectified parts are warranted for 5 years. Gun warranted for 90 days, parts and labor. Miller Electric Mfg. Co. International Headquarters Web Site An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125 www.MillerWelds.com Specifications Rated Output 160 A, 24.5 VDC at 60% Duty Cycle (Subject to change without notice.) Amperage Range Max. Open-Circuit Voltage 30 –210 A 34.5 Amps Input at Rated Output, 60 Hz 200(208) V 230 V KVA KW Wire Type and Diameter Wire Feed Speed 31.2 2.1* Solid/Stainless Steel: .023 – .035 in (0.6 – 0.9 mm) 50 –700 IPM (1.3 –17.8 m/min) 27.1 1.8* 6.36 5.45 0.51* 0.26* 210 A, 23 VDC at 30% Duty Cycle Max. Spool Size Dimensions Net Weight 12 in (305 mm) H: 30 in (762 mm) 190 lb (86 kg) W: 19 in (483 mm) Flux Cored: .030 – .045 in (0.8 – 1.2 mm) D: 40 in (1016 mm) *While idling. Note: Operating Temperature Range: -4˚ to +104˚ F (-20 to +40˚ C) Storage Temperature Range: -22˚ to +122˚ F (-30 to +50˚ C) Control Panel 50 40 60 1 2 1 3 70 30 20 10 1. Wire Feed Speed Control 2. Overtemp Light 3. Voltage Control 4 3 80 5 6 90 DO NO T SWITCH WHILE WELDING 100 7 2 Performance Data VOLT/AMP CURVES DUTY CYCLE CHART RATED OUTPUT 210 40 160 DC VOLTS WELD AMPS 300 20 10 0 100 30 40 50 60 % DUTY CYCLE 2 70 80 90 100 0 50 100 150 200 DC AMPERES 250 300 350 Standard Fully Loaded Features EZ-Change™ Low Cylinder Rack NEW! Patent-pending design — operators no longer need to lift cylinders. Cylinders now easily roll on and off our EZ-Change™ Low Cylinder Rack. Angled Wire Drive Angled industrial aluminum dual-gear drive system significantly improves wirefeeding and runs large spools of wire. Allows quick change of drive rolls without tools. Drive roll storage — no more lost drive rolls, extra drive rolls are conveniently stored next to drive motor. Operators no longer bump into and bend MIG gun and gun liner. Dual Front Handles Exclusive split handle with rubber grips designed to move machine easily and allow work lead and MIG gun to be stored independently. Handles provide protection for front panel and MIG gun during transportation. EZ-Access™ Consumable Compartment and Parameter Chart Convenient flip-down compartment holds parameter chart and storage for consumables. 3 Optional Fully Loaded Features Elevated Gun and Cable Rack #300 335 No more running over spool gun cables or cables dragging on the floor. Tangle-free, independent way to store spool gun cables, keeping them off of the floor. Elevated Gun and Cable Rack can be used with either a single or dual cylinder rack. (Elevated Gun and Cable Rack is included with the Dual EZ-Change™ Low Cylinder Rack.) Dual EZ-Change™ Low Cylinder Rack with Elevated Gun and Cable Rack #300 337 Dual cylinder rack allows for easy storage for two cylinders. EZ-Change™ Low Cylinder rack eliminates the need to lift cylinders on and off cylinder rack. No more running over spool gun cables or cables dragging on the floor. Tangle-free, independent way to store spool gun cables, keeping them off of the floor. 4 Genuine Miller Accessories M-25 Replacement Gun #169 594 10 ft (3 m) #169 596 12 ft (3.7 m) #169 598 15 ft (4.6 m) standard Gun shipped to run .030 –.035 in (0.8 – 0.9 mm) wire. Spoolmate™ 3035 Spool Gun #195 016 Spool gun for aluminum and other wires. 4 in spools; .023 –.035 in (0.6 – 0.9 mm) aluminum, steel and stainless steel. Rated at 150 amps, 60% duty cycle with 20 ft (6 m) cable assembly. Spoolmate™ 3035 25 ft Extension Cable Kit #194 996 Extends Spoolmate 3035 an additional 25 ft (7.6 m) from power source. Heavy-Duty Barrel for Spoolmate 3035 #195 375 Use for demanding applications, rated at 200 A, 60% duty cycle. Dual EZ-Change™ Low Cylinder Rack with Elevated Gun and Cable Rack #300 337 Dual cylinder rack allows operators to easily roll cylinders on and off the rack with no lifting. Gun and cable rack keeps cables off the floor and tangle free. Adapter Cable #195 287 Allows Spoolmatic® 15A or 30A to be used with Millermatic 212. Elevated Gun and Cable Rack #300 335 For use with single cylinder rack. (Included with Dual EZ-Change Low Cylinder Rack.) Protective Cover with Helmet Bag #195 142 Features side pocket, helmet bag and Flame graphic on side panel. Argon/Mixed Gas Regulator and Gas Hose #195 050 (Order from Miller Service Parts.) CO2 Regulator/Flow Gauge #212 492 Required if using 100% CO2 gas. (Order from Miller Service Parts.) Note: WFS is controlled at the machine, not the gun. 5 Consumables (Order from Miller Service Parts.) For M-25 Gun Contact Tips #087 299 .023/.025 in (0.6 mm) #000 067 .030 in (0.8 mm) #000 068 .035 in (0.9 mm) #000 069 .045 in (1.1 mm) #187 117 .035 in (0.9 mm) heavy-duty tip #187 118 .045 in (1.2 mm) heavy-duty tip Tapered Contact Tips #176 797 .030 in (0.8 mm) #176 793 .035 in (0.9 mm) #176 794 .045 in (1.2 mm) #169 726 5/8 in (16 mm) diameter orifice. Nozzle flush with contact tip. #169 727 5/8 in (16 mm) diameter orifice. Contact tip sticks out of nozzle 1/8 in (3.2 mm). Note: Drive roll kits include two drive rolls and an inlet guide. #169 724 1/2 in (13 mm) diameter orifice. Contact tip recessed 1/8 in (3.2 mm) into nozzle. V-Grooved Drive Roll Kits (solid wire) #204 579 .030 & .035 in (0.8 & 0.9 mm) Combination (Reversible) #087 131 .023/.025 in (0.6 mm) #079 594 .030 in (0.8 mm) #079 595 .035 in (0.9 mm) #169 725 5/8 in (16 mm) diameter orifice. Contact tip recessed 1/8 in (3.2 mm) into nozzle. V-Knurled Drive Roll Kits (Flux Cored or difficult-to-feed wire) #079 606 .035 in (0.9 mm) Spot Nozzles #176 238 Flat #176 240 Inside corner #176 242 Outside corner For Spoolmate 3035 Gun Tapered Nozzles Contact Tip Adapter #169 728 Drive Rolls Note: Tapered tips are recommended when using a tapered nozzle. #176 243 3/8 in (9.5 mm) diameter orifice #178 386 11/32 in (8.7 mm) diameter orifice Replacement Liners #194 010 .023/.025 in #194 011 .030 –.035 in (standard) #194 012 .035 –.045 in ™ Contact Tips (5 per package) #199 730 For .023/.025 in (0.6 mm) wire. #186 419 For .030 in (0.8 mm) wire. #186 406 For .035 in (0.9 mm) wire. Nozzle #186 405 Gun Convenience Kit #193 975 Contains: 5 – .035 in (0.9 mm) contact tips (#000 068) 5 – .045 in (1.2 mm) contact tips (#000 069) 2 – Tip adapters (#169 728) 1 – Nozzle adapter (#169 729) 3 – O-rings (#170 468) 2 – Shock washers (#169 730) 1 – 5/8 in (16 mm) diameter orifice nozzle (#169 726) Drive Roll (1) #199 731 For .023 in (0.6 mm) wire. #186 413 For .030/.035 in (0.8/0.9 mm) wire. Nozzles Note: Flush or stickout nozzles should be used for the short-circuit process. #200 258 Standard 1/2 in (13 mm) diameter orifice. Nozzle flush with contact tip. 6 Push Roll (1) #199 732 For .023 in (0.6 mm) wire. #186 414 For .030/.035 in (0.8/0.9 mm) wire. Notes 7 Ordering Information Steel Configuration Stock No. Description Millermatic 212 #907 324 200(208)/230 V, 60 Hz V-Groove Drive Roll Kits (solid wire) #087 131 #079 594 #079 595 #079 596 .023/.025 (0.6 mm) .030 (0.8 mm) .035 (0.9 mm) .045 (1.2 mm) V-Knurled Drive Roll Kits (flux cored) #079 606 #079 607 .035 (0.9 mm) .045 (1.2 mm) Contact Tips (10 per package) #087 299 #000 067 #000 068 #000 069 .023/.025 (0.6 mm) .030 (0.8 mm) .035 (0.9 mm) .045 (1.2 mm) Nozzles #169 724 #169 725 #200 258 #169 726 #169 727 1/2 in (13 mm) diameter, 1/8 in (3.2 mm) recessed 5/8 in (16 mm) diameter, 1/8 in (3.2 mm) recessed 1/2 in (13 mm) diameter, flush. Included with standard configuration 5/8 in (16 mm) diameter, flush 5/8 in (16 mm) diameter, 1/8 in (3.2 mm) exposed Millermatic® 212 Spool Gun Package (Also includes standard M-25 MIG gun) #951 068 200(208)/230 V, 60 Hz with Spoolmate™ 3035, dual cylinder rack, elevated gun and cable rack, regulator and hose Spool Gun Drive Roll #199 731 #186 413 .023 (0.6 mm) .030/.035 (0.8/0.9 mm) Spool Gun Push Roll #199 732 #186 414 .023 (0.6 mm) .030/.035 (0.8/0.9 mm) Spool Gun Contact Tips (5 per package) #199 730 #186 419 #186 406 .023/.025 (0.6 mm) .030 (0.8 mm) .035 (0.9 mm) Spool Gun Nozzle #186 405 ® Qty. Aluminum Configuration For M-25 gun consumables and Millermatic 212 drive rolls see steel configuration chart above. Accessories Gun Convenience Kit for Steel #193 975 M-25 Gun #169 594 #169 596 #169 598 Spoolmate™ 3035 Spool Gun #195 016 Spoolmate™ 3035 25 ft Extension Cable Kit #194 996 (Order from Miller Service Parts.) 10 ft (3 m), .023 –.035 in (0.6 – 0.9 mm) 12 ft (3.7 m), .023 –.035 in (0.6 – 0.9 mm) 15 ft (4.6 m), .023 –.035 in (0.6 – 0.9 mm) Spool gun for aluminum Heavy-Duty Barrel for Spoolmate™ 3035 #195 375 200 A, 60% Duty Cycle Adapter Cable #195 287 Allows Spoolmatic® 15A or 30A to be used with Millermatic 212 Dual EZ-Change™ Low Cylinder Rack with Elevated Gun and Cable Rack #300 337 Elevated Gun and Cable Rack #300 335 Protective Cover with Helmet Bag #195 142 Argon/Mixed Gas Regulator and Gas Hose #195 050 CO2 Regulator/Flow Gauge #212 492 Date: Total Quoted Price: Distributed by: Litho in USA For use with single cylinder rack. (Included with Dual EZ-Change Low Cylinder Rack.) Features side pocket, helmet bag and Flame graphic (Order from Miller Service Parts.) Required if using 100% CO2 gas. (Order from Miller Service Parts.) Price
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