OM-238 118C 2009−07 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 212 Auto-Set R ™ File: MIG (GMAW) Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 7 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 l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES FILS DE SOUDAGE peuvent provoquer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
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. A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions X Duty Cycle Do Not Switch While Welding Increase On Off Gas Metal Arc Welding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output Voltage Input Press To Reset V Wire Feed Output Volts U0 Rated No-Load Voltage (Average) SECTION 4 − INSTALLATION 4-1. Welding Power Source And MIG Gun Specifications Rated Output Amperage Range DC Max. Open Circuit Voltage DC 160 A at 24.
. 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. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com 4-4. Connecting To Weld Output Terminals 4 1 Do not place anything between weld cable terminal and copper bar. 2 Tools Needed: 3 3/4 in (19 mm) 803 778-A Correct Installation ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.
. A complete Parts List is available at www.MillerWelds.com 4-6. Installing Welding Gun 1 2 3 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. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. 4 1 2 3 805 424--A 4-7.
. A complete Parts List is available at www.MillerWelds.com 4-8. Connecting Spool Gun A. Spoolmate 200 1 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 2 3 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. 4 Positive Weld Output Terminal Connect weld cable to weld output terminal.
. A complete Parts List is available at www.MillerWelds.com B. Spoolmatic 15A Or 30A 1 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 2 3 Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel. 4 Positive Weld Output Terminal Connect weld cable to weld output terminal. 5 Regulator/Flowmeter Route shielding gas hose up to regulator/flowmeter. Connect gas hose to fitting on regulator/flowmeter. 2 .
. A complete Parts List is available at www.MillerWelds.com 4-9. Installing Gas Supply Tools Needed: 1 Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 2 1 Cap 2 Cylinder Valve 1-1/8, 5/8 in 7 Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.
. A complete Parts List is available at www.MillerWelds.com 4-10. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Installing 1 Or 2 lb Wire Spool Spindle Spindle Install these components onto spindle. To install either a 1 lb or 2 lb wire spool, follow the procedure as shown in the illustration. Customer supplied 2 in (51 mm) long piece of 3/4 in (19.
. A complete Parts List is available at www.MillerWelds.com 4-11. Positioning Jumper Links Check input voltage available at site. Tools Needed: 3/8 in 2 1 Jumper Links Access Door Open door. 2 200 VOLTS 230 VOLTS Jumper Link Label Check label − only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input voltage. 3 153 980-D Close and secure access door. 1 153 980-D / 804 911-A 4-12.
. A complete Parts List is available at www.MillerWelds.com 4-13. Selecting A Location And Connecting Input Power 1 18 in (457 mm) of space for airflow ! Do not move or operate unit where it could tip. 8 =GND/PE Earth Ground 10 7 9 L1 L2 6 4 5 2 1 3 L2 L1 230 VAC, 1 805 244-A ! ! ! Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit.
. A complete Parts List is available at www.MillerWelds.com 4-14. Threading Welding Wire 1 2 3 4 5 6 7 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 7 1 2 Tools Needed: 3 6 5 . Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. . Use pressure indicator Tighten scale to set a desired drive roll pressure.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 4 tMATERIAL THIC et KN 14 ga S E ot LTAG E 1/8” SS u 16ga VO 5 A 6 4 7 3 18 / ga 3 8 16” 20 2 ga 9 1/4” 1 22 ga 10 3/8” E SPEED WIR 60 70 50 40 80 90 30 100 20 10 .030” .035” Auto-Set* WELD WIRE DIAMETER OVERTEMP 1 1 Voltage Control Turn control clockwise inside white scale (1-10) to increase voltage (see weld parameter chart in welding power source or Section 5-2).
. A complete Parts List is available at www.MillerWelds.
. 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. .030” .035” Auto-Set* WELD WIRE DIAMETER t MAT ERIAL THIC KN 14 ga et E oS TAG L LTAG t O E E 1/8” SS u 16 ga V VO 5 5 A 6 6 4 4 7 3 7 18 / ga 3 3 16” 8 Activate Auto-Sett by selecting the diameter of the welding wire with the WIRE SPEED knob. Auto-Sett light comes on.
. 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) TERI AL T H t MA IC et 14 ga KN -S o E t TAG LTAG L O O E E u 16 ga V V 1/8” SS 5 5 6 6 A 4 4 7 7 3 18 / ga 3 3 8 16” 8 2. Number on left of slash is Voltage Knob Setting. (Example: 4 / 65) 6.5/75 6.5/60 6/95 6/70 5/55 4.5/70 4.8/60 4/50 4/60 4/50 3.5/45 3.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent . Maintain more often Disconnect power before maintaining. during severe conditions. l = Replace Reference Every 3 Months l Unreadable Labels Every 6 Months ~ Weld Terminals nl Weld Cables OR ~ Inside Unit n Apply Light Coat Of Oil Or Grease To Drive Motor Shaft 6-2.
. 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. 3 1 Correct Incorrect 4 2 5 1 2 3 4 5 Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll assembly. Tools Needed: Ref. 800 412-A 6-5.
. A complete Parts List is available at www.MillerWelds.com Wire Drive/Gun Trouble Wire feeding stops during welding. Remedy 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). Clean or replace wire inlet guide or liner if dirty or plugged (see welding gun Owner’s Manual).
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SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
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SECTION 8 − MIG WELDING (GMAW) GUIDELINES 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/ Power Source Gun Shielding Gas Gas Workpiece Work Clamp mig1_2007−05 / Ref.
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) (0.001 in = 1 ampere) 0.125 in = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in 30 − 90 A 0.030 in 40 − 145 A 0.
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.
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.
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. 1 1 2 2 3 Stringer Bead − Steady Movement Along Seam Weave Bead − Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 3 S-0054-A 8-6.
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. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
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. Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
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. Support hand on solid surface or use two hands. 8-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move.
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.
Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn 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. welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.
SECTION 9 − PARTS LIST 9-1. Drive Roll And Wire Guide Kits . Base selection of drive rolls upon the following recommended usages: 1 2 3 4 5 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). V-Knurled rolls for hard shelled cored wires (flux cored).
Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
