Miller Electric Millermatic 212 Auto-Set User manual

Miller Electric Millermatic 212 Auto-Set User manual
®
Millermatic Series
All-In-One MIG Buyer’s Guide
Everything You Need…
Everywhere You Need It.
Table Of Contents
Everything You Need…
Everywhere You Need It
4
A Complete Line Of
All-In-One MIG Welders
5
Fully Loaded Features For Best Value
5
How The Original All-In-One
MIG Welder Got Its Start
5
Just Ask, We’ll Answer
6
Designed For The Hobbyist,
Built For The Professional
8
Product Selector Guide
10
Product Highlights
12
3
®
Millermatic Series
Everything You Need…
Everywhere You Need It.
A Complete Line Of
All-In-One MIG Welders
Whether you need ultimate arc performance, power to weld
thick metals, pulsed MIG to weld thin-gauge aluminum, the
flexibility to go anywhere, or all of the above — the Millermatic
line from Miller provides you the optimal choice of all-in-one
MIG welders.
From farmers to metal fabricators, manufacturing plants to
home mechanics and hobbyists, there’s a Millermatic to fit
your application and budget. This guide is to help you decide
which machine is right for you and your applications, answer
popular questions, and provide detailed descriptions of
Miller’s full line of Millermatic welders.
Visit our new SmartSelector guide for more help
in choosing at MillerWelds.com/select
Millermatic®
Millermatic®
Millermatic® 211
™
™
140 Auto-Set 180 Auto-Set Auto-Set™ w/MVP™
Fully Loaded
Features For
Best Value
We asked welders how we
could make Millermatic MIGs
even better. Then we responded
with the most fully loaded
MIG welders available today.
Millermatic®
212 Auto-Set™
Millermatic®
252
Our Millermatic models are packed with the industry’s
most competitive offering of exclusive features and
standard capabilities. So they’re even more versatile,
even more reliable, and even easier to operate.
How The All-In-One
MIG Welder Got Its Start
Millermatic®
350/350P
®
Millermatic
®
Passport Plus
4
Miller Electric invented the Millermatic in 1971 by combining
a MIG power source, wire feeder, and gun into the first all-in-one
MIG welder. Today, several manufacturers offer this package,
but no one else offers such a complete product line, with
proven performance and innovative products designed to meet
your specific challenges. And no one else can back you with
nearly three decades of Millermatic reliability and excellence.
5
Just Ask, We’ll Answer
Here are popular questions we answer for our customers:
Why Should I Buy A MIG Welder?
Sometimes referred to as a wire welder, a MIG welder
creates an arc between a continuously fed filler metal
(consumable) electrode and the weldment.
Some advantages of MIG welding are:
• Welds light gauge material, including aluminum,
or thick plates
• Welds all common metals, including carbon steel,
stainless steel, and aluminum
• High-production welding speeds — MIG welding is
up to four times faster with nearly double the metal
deposition rate as the Stick welding process
• Less smoke and no slag to chip off
• An easy process to learn
Can MIG Equipment Also Be Used For
Flux Cored Welding?
Yes. Simply switch the polarity links near the drive system
to change from solid wire to flux cored wire.
Some advantages of Flux Cored welding are:
• Works as well as the Stick process on rusty or dirty metal
• Deep penetration for welding thick sections
• Portable — can eliminate the need for a shielding gas
bottle by using a gasless flux cored wire
• Gasless — also known as self-shielded flux cored wire,
is better suited for outdoor work
How Much Amperage Do I Need?
One way of classifying welders is by how much amperage
they can generate at a given duty cycle. Basically, amperage
equals heat.
Some approximate amperages for MIG welding mild steel are:
Thickness
Amperage
18 gauge
40 – 100
1/8 in
80 – 100
3/16 in
100 – 205
1/4 in
120 – 225
1/2 in
160+
Note: Amperage requirement
varies with wire size, welding
position, joint and shielding
gas being used.
6
Does Input Power (115 or 230 Volts) Make
A Difference?
Yes, because power in equals power out. A welder with
230 V/30 A of input can weld thicker metals than a 115 V/20
A welder. If you are unsure of what input power you have
available, or think you may need both, look for a machine
that can work off of either 115 or 230 V input power —
Miller offers two products for this, the Millermatic® Passport™
Plus and the Millermatic® 211 Auto-Set™ w/MVP™.
What Does Duty Cycle Mean?
Duty cycle is the amount of time during a 10-minute period
that a welder can operate at a given amperage without
overheating. For thicker metals or bigger jobs, choose a
welder with higher duty cycle capabilities.
Do I Want A Welder That Can Run Different
Wire Diameters?
Yes, for versatility. Using thinner wires, such as .023 or
.030 inch, minimizes the chance for burn-through on thin
materials. Conversely, using thicker wires, such as .045 inch
can help ensure excellent fusion on thicker metals.
Can Any MIG Unit Weld Aluminum?
Aluminum requires a faster wire feed speed because it melts
so quickly. If you plan to frequently weld aluminum, use a
specially designed MIG welding power source like the
Millermatic® 350/350P capable of the pulsed MIG process, or
a special aluminum feeding gun like a Spoolmatic® 15A/30A
or Spoolmate™ spool gun paired with a higher amperage
Millermatic. For the smaller amperage Millermatics like the
140 and 180 Auto-Set, the Spoolmate™ 100 Series spool gun
for aluminum is available.
Can I Use One Shielding Gas For Every Metal?
No. While many people weld on mild steel with straight CO2,
only a few machines produce good welds with low spatter
(such as the Millermatic Passport Plus). Most mild steel
applications call for a mixture of 75% Argon and 25% CO2.
Aluminum requires pure Argon, whereas stainless steel
welds best with a tri-mix.
7
Millermatic Series
®
Whether it’s thick steel or thin aluminum,
conventional MIG or Pulsed MIG, the
Millermatic line combines easy-to-use features
with ultimate arc performance to give you the
best all-in-one MIG welders in the industry.
Thermal overload protection — Designed to protect your
investment, every Millermatic is now equipped with built-in
thermal overload protection. . . not that you’ll need it.
Set-up and operation CD — Miller makes it easy to get
started. Every Millermatic comes standard with a CD that
goes through the basics of how to set up and operate your
machine to get optimal results.
Auto-Set™ Available on Millermatic 140, 180, 211 and 212.
The right setting automatically —
• Set the wire diameter, a
blue light shows that
Auto-Set is activated
• Dial in the thickness of
what you’re welding
• Start welding with the
exact parameters you need!
True Blue® 3-year
warranty — You
should never have an
issue with your
Millermatic. . . but just
in case. Welder is warranted for three years, parts and labor.
Original main power rectified parts are warranted for five
years. Gun is warranted for 90 days parts and labor.
No more burn through and rework — Correct Auto-Set
parameters make it easy to get quality welds, every time.
Weld flexibility with infinite voltage control — You also
have the flexibility to manually adjust weld parameters to the
exact settings you want. This comes in handy for broader
welding applications such as aluminum or stainless steel.
Aluminum solutions — Whether you purchase a
Millermatic 140 Auto-Set and a Spoolmate 100 Series spool
gun or a Millermatic 350P with an Aluma-Pro push-pull gun,
the entire Millermatic product line now offers an aluminum
solution for your application.
Material thickness gauge — To help
select parameters every Millermatic that
features Auto-Set now comes with a
material thickness gauge.
Aluminum drive systems — Every Millermatic features a
heavy-duty aluminum drive system designed to provide
superior feeding and durability. The toolless, quick-change
reversible drive rolls and easy-to-set scaled tension knob
make them the easiest to use in the industry.
8
9
®
Millermatic Series Product Selector
MATERIAL THICKNESS WELDED
IN A SINGLE PASS
MACHINE
Thin Gauge
3/16 in
1/4 in
FEATURES
APPLICATIONS
• Pulse-MIG (Pmodel)
• Push-Pull Gun/
Spool Gun Ready
Light Industrial
Manufacturing,
Aluminum
Fabrication
• Standard Timers
Menu
• Push-Pull Gun/
Spool Gun Ready
for Alum Apps
Farm & Ranch,
Light Industrial
Manufacturing,
Aluminum
Fabrication
• Spool Gun Ready
for Aluminum Apps
• Gun-On-Demand™
• Auto-Set™
Hobby &
Automotive,
Farm & Ranch,
Aluminum
Fabrication
230 VAC
150 A at
30% Duty Cycle
• Dual Voltage Input
• MVP™ Plug
• Auto-Set™
• Spool Gun
Compatible
Hobby &
Automotive,
Farm & Ranch,
Maintenance
& Repair,
230 VAC
150 A at
20% Duty Cycle
• MVP™ Plug
• 45 lbs
• Auto-Line™
• Spool Gun
Compatible
Maintenance
& Repair,
Light Fabrication,
Construction
• Auto-Set™
• Spool gun
Compatible
Hobby & Automotive,
Farm & Ranch, Light
Fabrication
• Auto-Set™
• Spool Gun
Compatible
Hobby &
Automotive,
Farm & Ranch,
Light Fabrication
5/16 in
200/230/460 or 460/575 VAC
300 A at 60% Duty Cycle,
1-Phase or 3-Phase
®
Millermatic
350/350P
®
Millermatic
252
208/230 VAC or 230/460/575 VAC
200 A at 60% Duty Cycle
NEW!
208/230 VAC
160 A at 60% Duty Cycle
Millermatic®
™
212 Auto-Set
NEW!
Millermatic® ™
211 Auto-Set
w/MVP™
115 VAC
90 A at 20% Duty Cycle
®
Millermatic
Passport ® Plus
115 VAC
110 A at 20% Duty Cycle
Millermatic®
™
180 Auto-Set
®
Millermatic
140 Auto-Set™
230 VAC
130 A at 30% Duty Cycle
115 VAC
90 A at
20% Duty Cycle
10
3/8 in
1/2 in
11
Millermatic® Passport® Plus
Which Product Is
Everything You Need?
Portability is #1 because not all
jobs can come to you —
weighing in at 45 lb and running
either 115 or 230 V, the Passport
Plus is great for steel, aluminum
and stainless steel jobs you need
to go to.
Millermatic® 140 Auto-Set™
Auto-Set™ — the exclusive Auto-Set
feature makes set up quick and easy.
Infinite voltage adjustment provides
broader operating range with finer
control than a tap machine.
Multi-Voltage
Plug (MVP™) —
Miller’s
exclusive MVP
allows
connection to 115 or 230 V receptacles
without tools.
Smooth-Start patent-pending
technology provides smooth, spatter-free starts — no pop gun
starts and no spatter to clean up.
“Tip Saver” shuts down output when tip is shorted to the work.
Extends contact tip life and protects internal components from
damage.
Heavy duty aluminum drive system.
Uses 4 or 8 in (102 or 203 mm) spools.
Max. — 3/16 in (4.8 mm)
Flexibility to use either external or internal gas cylinder.
Self-contained gas cylinder provides 25 minutes of arc time or
about 25 ft of weld on 3/16 in thick material with .030 in mild
steel wire.
Max. — 14 ga (1.9 mm)
Auto-Line™ provides state-of-the-art flexibility, automatically
connecting to 115/230 VAC, single-phase power.
Welding Capability Not to scale.
Mild Steel
Min. — 24 ga (0.8 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Min. — 18 ga (1.2 mm)
Excellent arc characteristics! Unit offers positive arc starts
and an extremely stable arc with minimal spatter on both
mixed gases and straight CO2.
Impact-resistant polymer case provides strength and
durability while protecting the internal components and
welding wire.
Recommended aluminum solution:
Spoolmate 100 Series #300 371.
Welding Capability Not to scale.
Millermatic® 180 Auto-Set™
Mild Steel
All the same great features as the
Millermatic ® 140 Auto-Set™ plus:
Max. — 3/8 in (9.5 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/4 in (6.4 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Welds thickest material in its class —
up to 5/16 in (7.9 mm) in a single
pass!
Recommended aluminum solution:
Spoolmate 100 Series #300 371.
Welding Capability Not to scale.
Mild Steel
Min. — 24 ga (0.8 mm)
Min. — 24 ga (0.8 mm)
Max. — 5/16 in (7.9 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/4 in (6.4 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
12
13
Millermatic® 211 Auto-Set™ with MVP™
Millermatic® 212 Auto-Set™
Welds thickest material in its class —
up to 3/8 in (9.5 mm) in a single pass!
Auto-Set™ — the exclusive Auto-Set
feature makes set up quick and easy.
Auto-Set™ — the exclusive Auto-Set
feature makes set up quick and easy.
Infinite voltage adjustment —
when used in manual mode
provides broader operating range
with finer control than a tap
machine.
Infinite voltage adjustment provides
broader operating range with finer
control than a tap machine.
Multi-Voltage Plug (MVP™)
— Miller’s exclusive MVP allows connection
to 115 or 230 V receptacles without tools.
Compatible with Spoolmatic®
15A/30A spool gun with wire feed speed control on the gun.
Saves time by reducing trips back to the machine.
Smooth-Start patent-pending technology
provides smooth, spatter-free starts — no pop
gun starts and no spatter to clean up.
Gun-On-Demand™ — simply pull the trigger for either gun and
you’re ready to weld. No wasted time installing modules and using
gas valve kits.
“Tip Saver” shuts down output when tip is shorted to the work.
Extends contact tip life and protects internal components from
damage.
Welding Capability Not to scale.
Heavy duty angled aluminum drive system.
15 ft (4.5 m) M-25 MIG gun features durable one-piece
handle, unicable outer jacket, trigger rated for one million
cycles, and steel spring coils protecting cable ends.
Welding Capability Not to scale.
Mild Steel
Min. — 24 ga (0.8 mm)
Max. — 3/8 in (9.5 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Mild Steel
Min. — 22 ga (0.9 mm)
Max. — 3/8 in (9.5 mm)
Min. — 14 ga (1.9 mm)
Max. — 3/8 in (9.5 mm)
Aluminum
Min. — 18 ga (1.2 mm)
Max. — 1/4 in (6.4 mm)
Recommended aluminum solution:
Spoolmate 100 Series #300 371.
w/Spoolmatic 15A
or 30A Spool Gun
Recommended aluminum solution:
Spoolmatic 15A or 30A #195 156 or
#130 831.
MVP™ (Multi-Voltage Plug) Configurations
115 V
115 V
230 V
230 V
14
15
Millermatic® 252
Millermatic® 350 & 350P
Infinite voltage control with
digital meters have self-calibrating
meters that permit presetting of
voltage and wire feed speed.
Ensures precise parameters and
accuracy.
Aluminum Pulse Hot Start™
(350P model) automatically
provides more arc power to
eliminate a “cold start” that is
inherent with aluminum starts.
Integrated digital timers come
complete with presettable
preflow/postflow, burnback, spot and delay (Stitch) timers.
Independent timers for MIG and spool gun.
Built-in Pulsed MIG programs
(350P model). All programmed
information is restored after each
power up — aluminum/steel/
stainless steel/metal core.
Superior aluminum MIG welding with direct connection of
optional XR push-pull guns and Spoolmatic 15A/30A spool
guns. No extra module to buy or install.
Infinite voltage control with digital meters have selfcalibrating meters that permit presetting of voltage and wire
feed speed. Ensures precise parameters and accuracy.
Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster, easier switching between MIG, push-pull
and spool guns.
Integrated digital timers come complete with presettable
preflow/postflow and spot timers. Independent timers for MIG
and push-pull guns.
Heavy duty angled aluminum drive system.
Fan-on-Demand cooling system only operates when needed
reducing power consumption.
Superior aluminum MIG welding with direct connection of
optional XR push-pull guns and Spoolmatic 15A/30A spool
guns. No extra module to buy or install.
15 ft (4.5 m) M-25 MIG gun features durable one-piece
handle, unicable outer jacket, trigger rated for one million
cycles, and steel spring coils protecting cable ends.
Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster, easier switching between MIG, push-pull
and spool guns.
Welding Capability Not to scale.
Heavy duty angled aluminum drive system.
™
Fan-On-Demand™ cooling system only operates when needed
reducing power consumption and keeping internal
components cleaner.
Mild Steel
Min. — 22 ga (0.9 mm)
Max. — 1/2 in (13 mm)
Min. — 14 ga (1.9 mm)
Max. — 1/2 in (13 mm)
Aluminum
Welding Capability Not to scale.
w/Spoolmatic 15A or
30A Spool Gun
Recommended aluminum solution:
Spoolmatic 15A or 30A #195 156 or
#130 831.
Mild Steel
Min. — 24 ga (0.8 mm)
Max. — 1/2 in (13 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/2 in (13 mm)
Aluminum
w/Aluma-Pro
Push-Pull Gun
Recommended aluminum solution:
25 ft. Aluma-Pro push-pull gun
#300 001
16
17
Most Popular Millermatic®
Accessories
Spool Guns for Aluminum Welding
Spoolmate™ 100 Series #300 371
For use with all Millermatic® 140 and 180
models, Millermatic® Passport® Plus,
Millermatic® 211 Auto-Set™ with MVP™
Spoolmatic® 15A or 30A
#195 156/130 831
For use with the
Millermatic® 212 Auto-Set™,
Millermatic® 252
XR-A™ Push-Pull Guns for Aluminum Welding
Aluma-Pro™- 15 or 25 ft
#300 000/300 001
For use with the
Millermatic® 252,
Millermatic® 350(P)
Standard #300 425 or
Premium #770 187
For Millermatic® 140 Auto-Set™,
180 Auto-Set™, and
Millermatic® 211 Auto-Set™ w/MVP™
Dual EZ-Change™ Low Cylinder
Rack with Elevated Gun and
Cable Rack #300 337
For Millermatic® 212 Auto-Set™ and
Millermatic® 252
Elevated Gun and Cable Rack
#300 335
For Millermatic® 212 Auto-Set™ and Millermatic® 252.
For use with single cylinder rack.
Dual Cylinder Rack #195 299
For Millermatic® 350/350P.
Replaces single cylinder rack.
XR™-A Pistol - 15 or 30 ft
#198 127/198 128
For use with the
Millermatic® 252,
Millermatic® 350(P)
Consumable Kits
Protective Covers
Heavy-duty, water- and mildew-resistant covers protect and
maintain the finish of your
welder.
#195 149
For Millermatic® 140
Auto-Set™, 180 Auto-Set,
and 211 Auto-Set
with MVP™.
Running Gear/ Cylinder Racks
#195 142
For Millermatic® 212
Auto-Set™, 252 and
350/350P.
18
M-10 Gun
#234 607 .023 (0.6 mm)
#234 608 .030 (0.8 mm)
#234 609 .035 (0.9 mm)
Contains 10 contact tips, 1
nozzle and 1 contact tip
adapter.
M-25 Gun
#234 610 .030 in (0.8 mm)
#234 611 .035 in (0.9 mm)
#234 612 .045 in (1.2 mm)
Contains 10 contact tips, 1 nozzle, 1 contact tip adapter, and
1 nozzle adapter.
19
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For detailed specification sheets or to
locate your nearest Miller distributor, call:
1-800-4-A-MILLER
(1-800-426-4553)
MillerWelds.com
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©2009 Miller Electric Mfg Co.
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