Miller Electric Millermatic 212 User manual

Processes
MIG (GMAW)
Flux Cored (FCAW)
Input Power
208/230 V, 1-Phase, 60 Hz
Industrial Applications
Metal Fabrication
Maintenance and Repair
Farm/Home
Light Industrial
Quick
Specs
Millermatic®212 MIG Arc Welding Power Source,
Wire Feeder and Gun Package
Issued September 2010 • Index No. DC/12.46
The Power of Blue® .
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)
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.
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.
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.
Line Voltage Compensation keeps
welding output constant even if
power input varies by +/- 10%.
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.
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.
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.
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) ➤
Manual mode allows you to manually
set weld parameters for broader
applications.
Compatible with Bobcat™welder/generators.
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.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
Equipment Sales US and Canada
Phone: [phone]
FAX: [phone]
International Phone: [phone]
International FAX: [phone]
Auto-Set™

2
Rated Output
160 A, 24.5 VDC
at 60% Duty Cycle
210 A, 22 VDC
at 30% Duty Cycle
Amperage
Range
30–210 A
Max.
Open-Circuit
Voltage
34.5
Net
Weight
178 lb
(81 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)
VOLT/AMP CURVES
0 50 100 150 200 250 300
0
5
10
15
20
25
30
35
AMPERES
VOLTS WELD AMPS
DUTY CYCLE CHART
30 100908070605040
100
160
210
% DUTY CYCLE
RATED OUTPUT
MAX
MIN
Performance Data
Control Panel
*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.
Auto-Set™Feature
The Millermatic®212 Auto-Set™eliminates the
guess work when setting weld parameters.
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.
Auto-Set Mode
3
4
5
1
2
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
• Turn wire speed control fully
clockwise to select Auto-Set
mode. Set the wire diameter
to either .030 or .035 in.
• 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!

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
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.
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
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.)

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™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.)
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 #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.)
CO2Regulator/Flow Gauge #237 702
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.
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
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.
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)
Consumables (Order from Miller Service Parts.)

7
Notes

Litho in USA
Distributed by:
Ordering Information
Steel Configuration Stock No. Description Qty. Price
Millermatic®212 Auto-Set™#907 405 200(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)
#204 579 .030/.035 (0.8/0.9 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
M-Series Gun Consumable Kits (for M-25) #234 607 .030 in (0.8 mm)
#234 608 .035 in (0.9 mm)
#234 609 .045 in (1.2 mm)
Aluminum Configuration
Millermatic®212 Spool Gun Package #951 177 200(208)/230 V, 60 Hz with Spoolmate™200, dual cylinder rack,
(Also includes standard M-25 MIG gun) elevated gun and cable rack, regulator and hose
Spoolmate 200 Contact Tips (5 per package) #199 730 .023 (0.6 mm) wire (Requires V-Knurled drive roll #136 135.)
#186 419 .030 (0.8 mm) wire
#186 406 .035 (0.9 mm) wire
Spoolmate 200 Nozzle #186 405
Optional Spoolmate 200 Barrel Assemblies #300 591 45-degree barrel
#300 592 9 in extension barrel
#300 593 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 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™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 #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 #195 142 Features side pocket
Argon/Mixed Gas Regulator and Gas Hose #195 050
CO2Regulator/Flow Gauge #237 702 Required if using 100% CO2gas. (Order from Miller Service Parts.)
Date: Total Quoted Price: