Miller Electric Millermatic 212 Users Manual A DC12 46 MM

Millermatic 212 to the manual ced8cd8e-7882-caa4-0dd0-557197d6c608

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Processes

MIG (GMAW)

Flux Cored (FCAW)

Input Power

200(208)/230 V

Industrial Applications

Light Fabrication

Garages/Body Shops

Farm/Ranch

Vocational/Technical Schools

Quick

Specs

Millermatic®212 MIG Arc Welding

Power Source

Issued August 2007 • Index No. DC/12.46

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.

The Power of Blue®

.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

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)

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!

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.

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.

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.

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!

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

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.

NEW!

Larger

work area —

now with longer

15-ft M-25 gun.

2

Rated Output

160 A, 24.5 VDC

at 60% Duty Cycle

210 A, 23 VDC

at 30% Duty Cycle

Amperage

Range

30 –210 A

Max.

Open-Circuit

Voltage

34.5

Net

Weight

190 lb

(86 kg)

Specifications (Subject to change without notice.)

Amps Input at Rated Output, 60 Hz

200(208) V 230 V KVA KW

31.2 27.1 6.36 5.45

2.1* 1.8* 0.51* 0.26*

Wire Type and

Diameter

Solid/Stainless Steel:

.023 –.035 in

(0.6 – 0.9 mm)

Flux Cored:

.030 – .045 in

(0.8 – 1.2 mm)

Wire Feed

Speed

50 –700 IPM

(1.3 –17.8

m/min)

Dimensions

H: 30 in

(762 mm)

W: 19 in

(483 mm)

D: 40 in

(1016 mm)

Max.

Spool

Size

12 in

(305 mm)

WELD AMPS

DUTY CYCLE CHART

30 100908070605040

100

160

210

VOLT/AMP CURVES

% DUTY CYCLE

0

0 50 100 150 200 250 300 350

10

20

030

40

DC AMPERES

DC VOLTS

RATED OUTPUT

Performance Data

40

50

30

20

10

60

70

80

90

100 7

6

5

4

3

2

1

DO NO T SWITCH

WHILE WELDING

3

1

2

Control Panel

1. Wire Feed Speed Control

2. Overtemp Light

3. Voltage Control

*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)

3

Standard Fully Loaded Features

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.

NEW!

Patent-pending design — operators

no longer need to lift cylinders. Cylinders

now easily roll on and off our EZ-Change™

Low Cylinder Rack.

4

Optional Fully Loaded Features

Elevated Gun and Cable 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.

#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.)

5

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.

Adapter Cable #195 287

Allows Spoolmatic®15A or 30A to be used

with Millermatic 212.

Note: WFS is controlled at the machine, not the gun.

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.

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.)

CO2Regulator/Flow Gauge #212 492

Required if using 100% CO2gas.

(Order from Miller Service Parts.)

Genuine Miller Accessories

6

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)

Contact Tip Adapter #169 728

Replacement Liners

#194 010 .023/.025 in

#194 011 .030–.035 in (standard)

#194 012 .035–.045 in

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.

#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).

#169 724

1/2 in (13 mm) diameter orifice. Contact tip

recessed 1/8 in (3.2 mm) into nozzle.

#169 725

5/8 in (16 mm) diameter orifice. Contact tip

recessed 1/8 in (3.2 mm) into nozzle.

Spot Nozzles

#176 238 Flat

#176 240 Inside corner

#176 242 Outside corner

Tapered Nozzles

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

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 Rolls

Note: Drive roll kits include two drive rolls and an

inlet guide.

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)

V-Knurled Drive Roll Kits

(Flux Cored or difficult-to-feed wire)

#079 606 .035 in (0.9 mm)

For Spoolmate™3035 Gun

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

Drive Roll (1)

#199 731 For .023 in (0.6 mm) wire.

#186 413 For .030/.035 in (0.8/0.9 mm)

wire.

Push Roll (1)

#199 732 For .023 in (0.6 mm) wire.

#186 414 For .030/.035 in (0.8/0.9 mm)

wire.

Consumables (Order from Miller Service Parts.)

7

Notes

Litho in USA

Distributed by:

Ordering Information

Steel Configuration Stock No. Description Qty. Price

Millermatic®212 #907 324 200(208)/230 V, 60 Hz

V-Groove Drive Roll Kits (solid wire) #087 131 .023/.025 (0.6 mm)

#079 594 .030 (0.8 mm)

#079 595 .035 (0.9 mm)

#079 596 .045 (1.2 mm)

V-Knurled Drive Roll Kits (flux cored) #079 606 .035 (0.9 mm)

#079 607 .045 (1.2 mm)

Contact Tips (10 per package) #087 299 .023/.025 (0.6 mm)

#000 067 .030 (0.8 mm)

#000 068 .035 (0.9 mm)

#000 069 .045 (1.2 mm)

Nozzles #169 724 1/2 in (13 mm) diameter, 1/8 in (3.2 mm) recessed

#169 725 5/8 in (16 mm) diameter, 1/8 in (3.2 mm) recessed

#200 258 1/2 in (13 mm) diameter, flush.

Included with standard configuration

#169 726 5/8 in (16 mm) diameter, flush

#169 727 5/8 in (16 mm) diameter, 1/8 in (3.2 mm) exposed

Aluminum Configuration

Millermatic®212 Spool Gun Package #951 068 200(208)/230 V, 60 Hz with Spoolmate™3035, dual cylinder rack,

(Also includes standard M-25 MIG gun) elevated gun and cable rack, regulator and hose

Spool Gun Drive Roll #199 731 .023 (0.6 mm)

#186 413 .030/.035 (0.8/0.9 mm)

Spool Gun Push Roll #199 732 .023 (0.6 mm)

#186 414 .030/.035 (0.8/0.9 mm)

Spool Gun Contact Tips (5 per package) #199 730 .023/.025 (0.6 mm)

#186 419 .030 (0.8 mm)

#186 406 .035 (0.9 mm)

Spool Gun Nozzle #186 405

For M-25 gun consumables and Millermatic 212 drive rolls see steel configuration chart above.

Accessories

Gun Convenience Kit for Steel #193 975

(Order from Miller Service Parts.)

M-25 Gun #169 594 10 ft (3 m), .023 –.035 in (0.6– 0.9 mm)

#169 596 12 ft (3.7 m), .023 –.035 in (0.6– 0.9 mm)

#169 598 15 ft (4.6 m), .023 –.035 in (0.6– 0.9 mm)

Spoolmate™3035 Spool Gun #195 016 Spool gun for aluminum

Spoolmate™3035 25 ft Extension Cable Kit #194 996

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 #300 337

Elevated Gun and Cable Rack

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

Argon/Mixed Gas Regulator and Gas Hose #195 050

(Order from Miller Service Parts.)

CO2Regulator/Flow Gauge #212 492 Required if using 100% CO2gas.

(Order from Miller Service Parts.)

Date: Total Quoted Price: