Miller Electric Millermatic Reach Wire Feeder User manual

Miller Electric Millermatic Reach Wire Feeder User manual
Millermatic 212 Auto-Set
Issued September 2010 • Index No. DC/12.46
®
Quick
Specs
Industrial Applications
Processes
Metal Fabrication
Maintenance and Repair
Farm/Home
Light Industrial
MIG (GMAW)
Flux Cored (FCAW)
Input Power
208/230 V, 1-Phase, 60 Hz
™
MIG Arc Welding Power Source,
Wire Feeder and Gun Package
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 178 lb (81 kg)
The Power of Blue .
®
Comes Complete With:
7 ft (2.1 m) power cord and plug
(208/230 V model only)
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
Factory-installed running gear with
EZ-Change™ Low Cylinder Rack
.030/.035 in reversible
drive rolls
Set-up and operation
interactive CD
Material thickness
gauge (#229 895) ➤
Auto-Set is a breakthrough control that
automatically sets your welder to the
proper parameters. Auto-Set makes set
up very simple and gives you precise
settings instantly. See page 2 for details.
™
Manual mode allows you to manually
set weld parameters for broader
applications.
Infinite voltage control replaces “tap”
settings which means that you now can
“dial in” precise weld voltage and wirefeed
speed when using the Manual Mode.
Compatible with Spoolmate™ 200
spool gun! The
Spoolmate 200
with wirefeed speed
control on the gun saves
time for the operator by
eliminating the need to go
back to the machine to change the
spool gun wirefeed speed.
EZ-Access™ Consumable Compartment
and Parameter Chart — with convenient
new flip-down compartment that provides
fast access to parameter chart and
consumables. See page 3 for more
information.
Line Voltage Compensation keeps
welding output constant even if
power input varies by +/- 10%.
No more replacing mechanical
output contactors. Our built-in
solid-state contactor circuit makes
wire electrically “cold” until trigger is
pulled, and gives you life-long welding
output and performance.
Compatible with
the Millermatic®
Reach Wire
Feeder. MIG Gun
sold separately.
(See page 5
for more
information.)
Reduce maintenance and operating
costs with our Fan-On-Demand™ cooling
system only operates when needed,
reducing power consumption and
contaminants drawn into the machine.
Compatible with Bobcat™ welder/generators.
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.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
Auto-Set Feature
™
Auto-Set Mode
The Millermatic® 212 Auto-Set™ eliminates the
guess work when setting weld parameters.
• Turn wire speed control fully
clockwise to select Auto-Set
mode. Set the wire diameter
to either .030 or .035 in.
Use Auto-Set when you want the speed,
convenience and confidence of pre-set controls.
Simply set the wire diameter, set the material
thickness, and go! The Auto-Set control
automatically sets your welder to the proper
parameters. It is available when welding mild
steel with solid wire and only works with .030
and .035 solid wires and C25 shielding gas
(75% Argon, 25% CO2).
You can also set the weld parameters manually.
Simply refer to the flip-down parameter chart,
and set the voltage and wire feed speed to the
recommended settings for your application.
Specifications
Rated Output
160 A, 24.5 VDC
at 60% Duty Cycle
• Light indicates Auto-Set
mode is activated.
• Set the material thickness within Auto-Set range for 22 gauge
through 3/8 in mild steel. The welder automatically sets itself
to proper parameters, and is ready to weld!
(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, 22 VDC
at 30% Duty Cycle
Max.
Spool
Size
Dimensions
Net
Weight
12 in
(305 mm)
H: 30 in
(762 mm)
178 lb
(81 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)
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Performance Data
Control Panel
DUTY CYCLE CHART
RATED OUTPUT
3
1
WELD AMPS
210
160
4
100
30
40
2
50
60
70
80
90 100
% DUTY CYCLE
5
VOLT/AMP CURVES
35
30
MAX
1. Infinite Voltage Control/Material Thickness
2. Diagnostic Indicator Light
3. Wire Feed Speed Control/Wire Diameter
4. Auto-Set Light
5. Power On Indicator Light
VOLTS
25
20
MIN
15
10
5
0
0
50
100
150
AMPERES
2
200
250
300
Standard Fully Loaded Features
EZ-Change™ Low Cylinder Rack
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
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
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
No more running over spool gun cables
or cables dragging on 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™ 200 Spool Gun
#300 497
Reliable and economical spool gun perfect
for hobbyists and light fabricators who
weld aluminum. Handles .030 –.035 in
(0.8 – 0.9 mm) aluminum and .023 –.035 in
(0.6 – 0.9 mm) steel/stainless steel wires.
Rated at 160 amps, 60% duty cycle with 20 ft
cable assembly. For detailed information,
see Spoolmate literature, Index No. M/1.47.
Spoolmatic® 15A Spool Gun #195 156
Spoolmatic® 30A Spool Gun #130 831
Ideal for aluminum welding jobs. 200 amp,
100% duty cycle, air-cooled, 1 lb spool
gun with your choice of 15 ft or (4.6 m)
30 ft (9.1 m) cable assembly. For detailed
information, see Spoolmatic literature,
Index No. M/1.2.
Millermatic Reach
#907 438 25 ft (7.6 m)
Extend your Millermatic work envelope up
to 40 feet! No more moving the machine
and pulling primary power cables around
the shop. Or use as a dual feeder option!
No more downtime changing spools and
drive rolls. For use with Millermatic 212
Auto-Set, 251, 252 and 350/350P.
(MIG Gun sold separately.)
Protective Cover #195 142
Features side pocket.
(Not for use with Dual Cylinder Rack or
Elevated Gun and Cable Rack.)
Argon/Mixed Gas Regulator and Gas Hose
#195 050
(Order from Miller Service Parts.)
CO2 Regulator/Flow Gauge #237 702
Required if using 100% CO2 gas.
(Order from Miller Service Parts.)
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.)
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.
Drive Rolls
#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.
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)
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
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.
6
M-Series Consumable Kits
#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.
Note: Drive roll kits include two drive rolls and an
inlet guide.
Notes
7
Ordering Information
Steel Configuration
Stock No.
Description
Qty.
Millermatic 212 Auto-Set
#907 405
200(208)/230 V, 60 Hz
V-Groove Drive Roll Kits (solid wire)
#087 131
#079 594
#079 595
#204 579
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.030/.035 (0.8/0.9 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
M-Series Gun Consumable Kits (for M-25)
#234 607
#234 608
#234 609
.030 in (0.8 mm)
.035 in (0.9 mm)
.045 in (1.2 mm)
Millermatic® 212 Spool Gun Package
(Also includes standard M-25 MIG gun)
#951 177
200(208)/230 V, 60 Hz with Spoolmate™ 200, dual cylinder rack,
elevated gun and cable rack, regulator and hose
Spoolmate 200 Contact Tips (5 per package)
#199 730
#186 419
#186 406
.023 (0.6 mm) wire (Requires V-Knurled drive roll #136 135.)
.030 (0.8 mm) wire
.035 (0.9 mm) wire
Spoolmate 200 Nozzle
#186 405
Optional Spoolmate 200 Barrel Assemblies
#300 591
#300 592
#300 593
®
™
Aluminum Configuration
45-degree barrel
9 in extension barrel
Heavy-duty barrel
For M-25 gun consumables and Millermatic 212 Auto-Set drive rolls, see steel configuration chart above.
Accessories
M-25 Gun
#169 594
#169 596
#169 598
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)
Spoolmate™ 200
#300 497
20 ft (6 m), 160 A, .030 –.035 in (0.8– 0.9 mm) for aluminum,
.023 –.035 in (0.6– 0.9 mm) for steel/stainless steel wires
Spoolmatic® 15A
#195 156
15 ft (4.6 m), 200 A, .023–1/16 in (0.6–1.6 mm) for aluminum
Spoolmatic® 30A
#130 831
30 ft (9 m), 200 A, .023–1/16 in (0.6–1.6 mm) for aluminum
Millermatic Reach Wire Feeder
#907 438
25 ft (7.6 m) cable assembly. (MIG Gun sold separately.)
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack
#300 337
Elevated Gun and Cable Rack
#300 335
For use with single cylinder rack.
(Included with Dual EZ-Change Low Cylinder Rack.)
Protective Cover
#195 142
Features side pocket
Argon/Mixed Gas Regulator and Gas Hose
#195 050
CO2 Regulator/Flow Gauge
#237 702
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Required if using 100% CO2 gas. (Order from Miller Service Parts.)
Price
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