TM-238119L 2019−07

Eff. w/Serial Number LJ180755B And

Following
Processes
MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source

and Wire Feeder

Millermatic 212
R

Auto-Set
™

For product information, File: MIG (GMAW)

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 INFORMATION ON OLDER UNITS

. This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com

. Due to a change in business unit of manufacture, original models have a serial number designation with a B suffix (for example, LJ180755B), while
later models have a serial number designation suffix of N (for example MA290011N). When contacting the Factory Service Department, please
be sure to note the proper serial number suffix for the machine.

. Eff w/MA440832N, Thermal Overload Light LED3 has enhanced functionality (see Troubleshooting section) and Run-In was added.
. Eff w/MK230040N, The wire spool assembly has changed. Order the correct parts based on the serial number of the unit.
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-3. Welding Power Source And MIG Gun Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-5. Welding Power Source Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-2. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-3. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-4. Installing Work Cable And Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-6. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-7. Connecting Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-8. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-9. Installing MIG Wire Spool and Adjusting Hub Tension (Prior to MK230040N) . . . . . . . . . . . . . . . . . . . 12
4-10. Installing Wire Spool And Adjusting Hub (Eff w/Serial No. MK230040N) . . . . . . . . . . . . . . . . . . . . . . . 13
4-11. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-13. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-14. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Run-In Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-4. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-2. Diagnostic Light (Eff w/MA440832N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-4. Troubleshooting Circuit Diagram For Welding Power Source (Prior To MA440832N) . . . . . . . . . . . . . 30
7-5. Troubleshooting Circuit Diagram For Welding Power Source (Eff w/MA440832N) . . . . . . . . . . . . . . . 32
7-6. Readings For Troubleshooting Circuit Diagram (All Models) (Use With Section 7-5) . . . . . . . . . . . . . 34
7-7. Waveforms For Section 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-8. Main Control Board PC1 Testing Information (Use With Section 7-9) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-9. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-10. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
 TABLE OF CONTENTS

SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-2. Unit Overload Protection And Tip Saver/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-3. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-4. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
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. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train-
ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog-
nize and avoid the hazards involved.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit.
D Do not work on equipment unless it has been verified that the ma-
chine case is not energized.
D Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
D Turn off unit, disconnect input power, and discharge input capaci-
tors according to instructions in Manual before touching any parts.
Millermatic 212 Auto−Set
OM-238118G - 2019-05, safety_stm 2018-01
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
ARC FLASH can kill.
Arc flash is the rapid and violent release of energy that
occurs when electric current leaves its intended path
and arcs to other conductors or to ground. Arc flash
can be caused by equipment failure (faulty insulation,
corrosion, dust) improper installation, human error (improper tool
placement), and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk.
D Do not work on energized equipment unless an assessment of
arc flash risk from the electrical supply circuit has been conducted
by a qualified person and you have been trained in safe work prac-
tices by your employer.
D Follow requirements in NFPA 70E for safe work practices and
Personal Protective Equipment (PPE).
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
TM-238119 Page 1
 EXPLODING PARTS can injure.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing me-
ter lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of ade-
quate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep away from pinch points such as drive
rolls.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
1-3. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals in-
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
TM-238119 Page 2
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
install, test, and service H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
formation at the beginning of the manual and in each section.
D Perform installation, maintenance, and service according to the
Technical Manual, industry standards, and national, state, and
local codes.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
Millermatic 212 Auto−Set
 SECTION 2 − DEFINITIONS
2-1. Symbols And Definitions

Wire Feed Output

X Duty Cycle
Do Not Switch
While Welding

V Volts Increase On Off

Gas Metal Arc

Wire Feed Spool
Welding (GMAW) Gas Input Gas Output
Gun
Gun

Voltage Input Press To Reset U0 Rated No-Load

Voltage (Average)

SECTION 3 − SPECIFICATIONS

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.
For future reference, write serial number in space provided on back cover of this manual.

3-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.millerwelds.com/eula and are incorporated by reference herein.

3-3. Welding Power Source And MIG Gun Specifications

Amps Input at Rated Output, 60 Hz, Single-Phase
Rated Output Amperage Max. Open Circuit
Range DC Voltage DC 200 (208) V 230 V KVA KW
160 A at 24.5 VDC, 30-210 34.5 31 28 6.2 5.2
60% Duty Cycle 1.9* 1.7* 0.39* 0.25*
210 A at 22 VDC
30% Duty Cycle
*While idling

Wire Type and Diameter Wire Feed Maximum Dimensions Net Weight
Speed Spool Size Without Gun
Solid Steel Stainless Steel Flux Cored 50−700 IPM 12 in. (305 H: 30 in. (762 mm) 183 lb
(1.3−17.8 mm) Diameter W: 19 in. (483 mm) (83 kg)
.023 − .035 in. .023 − .035 in. .030 − .045 in. m/min) D: 40 in. (1016 mm)
(0.6 − 1.2 mm) (0.6 − 0.9 mm) (0.8 − 1.2 mm)
Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C

3-4. Environmental Specifications

A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 2014−06

B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range

-4 to 104°F (−20 to 40°C) −22 to 122°F (−30 to 50°C)

*Output is derated at temperatures above 104°F (40°C). Temp_2016- 07

Millermatic 212 Auto−Set TM−238119 Page 3

3-5. 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.

60% Duty Cycle At 160 Amperes 30% Duty Cycle At 210 Amperes

6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 256 218-A

3-6. Volt-Ampere Curves

Volt-ampere curves show minimum
35 and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
30 between curves shown.

25

20
VOLTS

15

10

0
0 100 200 300
AMPERES
va_curve1 4/95 − 238 553-A

TM−238119 Page 4 Millermatic 212 Auto−Set

 SECTION 4 − INSTALLATION

4-1. Selecting A Location

! Do not move or operate unit where it could tip.

Movement

Location And Airflow

! Special installation may be
required where gasoline or
1 volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1 Line Disconnect Device
Locate unit near correct input
power supply.

18 in.
(460 mm)

18 in.
(460 mm)

loc_smallmig2 2018-05 161-122

Millermatic 212 Auto−Set TM−238119 Page 5

4-2. Weld Output Terminals And Selecting Cable Sizes
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Welding Duty Cycle Duty Cycle
Amperes 10 − 100% Duty Cycle
AWG (mm2) AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08

4-3. Connecting Weld Output Cables

2
6
3
1

Tools Needed: 5
3/4 in. (19 mm)

803778-B

! 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 ma-
chine.
. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
1 Correct Weld Cable Connection
2 Incorrect weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output ter-
minal. Slide weld cable terminal onto weld
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar.
connecting weld output cables 3−2010

TM−238119 Page 6 Millermatic 212 Auto−Set

4-4. Installing Work Cable And Clamp
1 Work Cable
2 Boot
Route cable through front panel
opening. Slide boot onto work
cable.
3 Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.

Tools Needed:
3/4 in.
Ref. 804909-B

4-5. Installing Welding Gun

1 Drive Assembly
2 Gun Securing Knob
3 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

3
1 2

804913--B

Millermatic 212 Auto−Set TM−238119 Page 7

4-6. Setting Gun Polarity For Wire Type
1 Polarity Changeover Label
Information
Always read and follow
manufacture’s recommended
Changing Polarity polarity.

Wire Drive Work Clamp Lead

Assembly Lead

D
D

+ Positive Terminal - Negative Terminal

Shown as shipped − Electrode Positive (DCEP): For

solid steel, stainless steel, aluminum, or flux core with
gas wires (GMAW).
Electrode Negative (DCEN): Reverse lead connections
at terminals from that shown above for gasless flux core
wires (FCAW). Drive assembly becomes negative.

3/4, 11/16 in.

Ref. 190821-A

Notes

TM−238119 Page 8 Millermatic 212 Auto−Set

4-7. Connecting Spool Gun
A. Spoolmate 200

1 Gun Trigger Plug

Insert plug into receptacle, and
tighten threaded collar.
2 Weld Cable
3 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.
5 Regulator/Flowmeter
Route shielding gas hose up to
2 regulator/flowmeter. Connect gas
hose to fitting on regulator/flowmeter.
3
. Two welding guns, a MIG gun
and a spool gun, can be
connected to the welding
power source at the same time,
1 but only one welding gun may
be in use at any one time. If the
triggers of both welding guns
are pulled at the same time, the
weld output and wire feed
motor are disabled.
5

Tools Needed:
3/4, 5/8 in.
804910-B / 243737-A

Millermatic 212 Auto−Set TM−238119 Page 9

B. Spoolmatic 15A Or 30A

1 Gun Trigger Plug

Insert plug into receptacle, and
tighten threaded collar.
2 Weld Cable
3 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/flowme-
ter.
2
. Two welding guns, a MIG gun
3 and a spool gun, can be
connected to the welding
power source at the same time,
but only one welding gun may
be in use at any one time. If the
1 triggers of both welding guns
are pulled at the same time, the
weld output and wirefeed motor
are disabled.

Tools Needed:
3/4, 5/8 in.
804910-B

TM−238119 Page 10 Millermatic 212 Auto−Set

4-8. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
Tools Needed: 1 1 Cap
1-1/8, 5/8 in. 2 Cylinder Valve
Remove cap, stand to side of
2 valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3 3 Cylinder
7 4
4 Regulator/Flowmeter
Install so face is vertical.
Argon Gas Or Mixed Gas
5 Regulator/Flowmeter Gas
Hose Connection
1 6 Welding Power Source Gas
5
Hose Connection
Connect customer supplied gas
2 hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
3 7 Flow Adjust
8 9 Typical flow rate is 25 to 35 cfh
(cubic feet per hour). Check wire
manufacturer’s recommended
CO2 Gas flow rate.
8 CO2 Adapter (Customer
Supplied)
9 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
6 cylinder.

Rear Panel

Ref. 805244-A / 804654-A

Millermatic 212 Auto−Set TM−238119 Page 11

4-9. Installing MIG Wire Spool and Adjusting Hub Tension (Prior to MK230040N)

Use compression spring When a slight force is needed

with 8 in. (200 mm) spools. to turn spool, tension is set.

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire

spool, follow the procedure as
Spindle
Install these shown in the illustration.
Spindle
components
onto spindle.

Customer supplied 2 in.

(51 mm) long piece of 3/4 in.
(19.1 mm) PVC pipe

Remove these
components
from spindle.

Tools Needed:

15/16 in.
805253-A

Notes

TM−238119 Page 12 Millermatic 212 Auto−Set

4-10. Installing Wire Spool And Adjusting Hub (Eff w/Serial No. MK230040N)

Hand tighten knob clockwise.

When a slight force is needed
to turn spool, tension is set.

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire

spool, follow the procedure as
shown in the illustration.

Spindle

Remove these
components
from spindle.

Spindle

Order two additional 5/8 washers

Part No. 605941

Install these
components
onto spindle.

Order additional spring

Part No. 186437

282945A

Millermatic 212 Auto−Set TM−238119 Page 13

4-11. Positioning Jumper Links
Tools Needed: Check input voltage available at
site.
3/8 in. 1 Jumper Links Access Door
2
Open door.
2 Jumper Link Label
Check label − only one is on unit.
200VOLTS 230VOLTS
3 Input Voltage Jumper Links
Move jumper links to match input
voltage.
3
153980-D Close and secure access door.

153980-D / 804911-B

4-12. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

60 Hz Single
Phase
Input Voltage (V) 200 230
Input Amperes (A) At Rated Output 31 28
Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 35 30
Normal Operating Fuses 3 45 40
Min Input Conductor Size In AWG 4 10 10
89 118
Max Recommended Input Conductor Length In Feet (Meters)
(27) (36)
Min Grounding Conductor Size In AWG 4 10 10

Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

TM−238119 Page 14 Millermatic 212 Auto−Set

4-13. Connecting 1-Phase Input Power

6
=GND/PE Earth Ground
10

L1
8 L2 9

4
2

1
3

L2 L1

230 VAC, 1

805244-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.
! Always connect green or
green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.
! Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
1 Rating Label
Supply correct input power.
2 Plug (NEMA Type 6-50P)
3 Receptacle
[NEMA Type 6-50R (Customer
Supplied)]
4 Input Power Cord.
Connect directly to line disconnect device if
hard wiring is required.
5 Disconnect Device (switch shown in
the OFF position)
6 Disconnect Device Grounding Terminal
7 Disconnect Device Line Terminals
8 Green or Green/Yellow Grounding
Conductor
9 Black and White Input Conductor (L1
and L2)
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 4-12 (fused
disconnect switch shown).
Connect plug to receptacle if hard wiring
method is not used.
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.

Millermatic 212 Auto−Set TM−238119 Page 15

4-14. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
7 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. Push wire thru guides into gun;
continue to hold wire.

Tighten
. Use pressure indicator
scale to set a desired
drive roll pressure.

1 Pressure
2 Indicator
3 Scale
4

Close and tighten pressure Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.

Tighten

1
2
3
WOOD 4

Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Close
comes out of gun. Reinstall Tighten knob enough to prevent slipping. and latch door.
contact tip and nozzle
Ref. 804913-A

TM−238119 Page 16 Millermatic 212 Auto−Set

 SECTION 5 − OPERATION
5-1. Controls
3
1 Voltage Control
Turn control clockwise inside white scale
(1-10) to increase voltage (see weld
parameter chart in welding power source
or Section 5-4).
2 Wire Speed Control
Turn control clockwise inside white scale
(10-100) to increase wire feed speed. (see
weld parameter chart in welding power
source or Section 5-4).
Millermatic 212 Auto−Set
3 Diagnostic Light
The Diagnostic light provides diagnostic
modes to help troubleshoot various
malfunctions with the unit (see Section
7-2).
4 Auto−Set™ Light
To use Auto−Set™ mode, rotate Wire
Speed control inside blue area for the
applicable Weld Wire Diameter,
Auto−Set™ light will turn on, and the unit will
provide the appropriate wire feed speed for
Ref. 248457-A
the material thickness selected using the
Voltage control (see Section 5-4).
Rotate Voltage control inside blue scale (22
ga to 3/8”) for the applicable material
thickness and the unit will provide the
appropriate voltage within the range of the
selected material thickness and the selected
Weld Wire Diameter (see Section 5-4).
5 Power Light
Light illuminates when input power is
turned on.
TM−238119 Page 17
5-2. Power Switch
1 Power Switch
Use switch to turn power on and off.

Ref. 804908-A

5-3. Run-In Setting

Run-In is the speed of the wire prior to the welding arc being struck. This setting is a percentage of the wire feed speed the unit is set to for welding.
Programming values range from 25 − 100%.

The standard MIG gun has a separate Run-In from the Spoolmatic 15/30A spool gun. Both Run-Ins are set to 50% from the factory for optimal arc starts.

To adjust run-in, first turn off the unit. While the unit is off, pull the trigger on the gun that is going to be adjusted, then turn on the unit. The yellow OVER-
TEMP light will flash once indicating a trigger error. Turn the wire speed control to minimum, then turn the wire speed control to maximum. The yellow
light will turn off and the Auto-Set light will flash indicating that Run-In is now settable. Turn the wire speed control to the desired percentage. For ex-
ample, setting the wire speed control to 60 will set the run-in percentage to 60%. Finally, release the trigger to save the run-in setting.

TM−238119 Page 18 Millermatic 212 Auto−Set

Notes

Millermatic 212 Auto−Set TM−238119 Page 19

 5-4. Weld Parameter Chart

Auto-Sett - SIMPLE SETUP FOR WELDING MILD STEEL

Example: .035” diameter wire, welding 16 ga. material.

Activate Auto-Sett by selecting

.030” Auto-Set* the diameter of the welding wire
WELD WIRE with the WIRE SPEED knob.
.035” DIAMETER Auto-Sett light comes on.

Select thickness of the mild steel

t MAT ERIALTHIC being welded with the VOLTAGE
et 14 ga KN knob.
-oS LTAG E
t
u 16 ga V O
VO LTAG E
E 1/8” SS Setup complete.
A 5
5 6
6
18
4
4 7
7 3
/
ga 3 3 16”
8
8

7.5/85
7.5/75

9/65
6/75
7/60
6.5/50
Stainless steel
8.5/90
9/80
Aluminum with Aluminum
Spoolmate 200 4043 ER 10/6
Spoolgun
Aluminum
5356 ER

Aluminum with Aluminum

Spoolmatic 15/30A 4043 ER
Spoolgun MAX/6
Aluminum
5356 ER

TM−238119 Page 20 Millermatic 212 Auto−Set

 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) t MA
TERI AL T H
IC
et 14 ga KN
o-S E
t
u 16 ga V VO
O LTAG
LTAG E
E 1/8” SS
2. Number on left of A 5
5 6
6
slash is Voltage 18
4
4 7
7 3
ga /
Knob Setting. 3
3
8 16”
8
(Example: 4 / 65)

6/95 4.5/70 4/60 3.5/50 3.5/45 3/40 2.5/35

6.5/75 6/70 4.8/60 4/50 3/45 2.5/40 2/38 2/31
6.5/60 5/55 4/50 3.5/45 3/40 2.5/35 2/30 2/28
7.5/80 6.5/70 6/60 5.5/55 4.5/45 3.7/35 4/35
8/70 7/60 5.5/50 5/45 4.5/40 4/35 3.7/31
8/60 7/55 5/45 4.8/40 4.5/32 4/28
4.5/65 4/60 3.5/50 3/40 2.5/32
6/55 5/50 4/40 3/30
5.5/45 4/40 3.5/35

8/90 7/75 6/60 5.8/50 5.5/40 5/35

7.5/85 7/75 6.5/65 6/55 5.2/48 4.8/40 4.5/33
8/70 7/60 6/50 5.5/45 5/40 4.5/35
10/6 7.5/4 5/3 3.5/3.25 3/3
8.5/4.5 7.5/3.5 5/2.75 2.5/2.5 1.5/2.25
7.5/5.5 6.5/5 2.5/4.5 1.75/4
8.5/5.5 7.5/5 6.5/4.5 2.5/4 1.75/3.5
9/7 7.8/6 6/5 3.5/4.8 3/4.2
8.5/5.5 7.5/5 6.5/4.5 3.5/4.5 3/4
7.5/MAX 6.5/8.5 3.5/7 3/6.5
8.5/9 7.8/8.5 6.5/7.5 3.5/6 3/5.5

238552-F

Millermatic 212 Auto−Set TM−238119 Page 21

 SECTION 6 − THEORY OF OPERATION
1 Power Switch S1
A. Block Diagram
Turns unit on and off.
2 Input Terminal Board TE1
Provides means for operation on
different input voltages.
3 Main Transformer T1
Supplies power to weld output cir- 1 2 3
cuit, main control board PC1, and
other control circuits. Power Input
Switch Terminal
4 Fan Motor FM S1 Board TE1
5
Controlled by thermistor, and con-
trol board PC1. Rectifier
Main SR1
5 Rectifier SR1 Single-Phase Transformer
Line Input Power 4 T1
SR1 Changes the AC output from
T1 to full-wave rectified DC. Fan Motor
FM SCR
6 Capacitor Bank C5, Burden Gate
Resistor R1 Pulses
C5 filters the DC output voltage of
SR1; R1 discharges C5 when unit is
not triggered.
7 Stabilizer Z1
Smooths out current to positive (+)
output terminal. 11 10 Voltage
Start winding and contactor W Feedback
changes characteristic of stabilizer Thermistor RT
Z1 during arc start operation.
8 Positive (+) And Negative (−)
24 VAC
Output Terminals
Main
Provide weld output and allow 12 Control
changing of output polarity. Board PC1
9 Wire Drive Assembly Gas Valve
GS1
Feeds welding wire through liner
and gun. 24 VAC

Contactor W

20

Power
LED3

13

Wire Drive Pulse Width

Motor PM Modulation

TM-238119 Page 22 Millermatic 212 Auto-Set

 10 Main Control Board PC1
Controls weld output by changing
SCR gate pulses (conduction times)
after comparing voltage feedback
signal to selected voltage signal.
Monitors unit temperature.
Controls wire speed by changing the
pulse width modulation signal (wider
or narrower pulses meaning more or
less voltage to motor) after compar-
ing motor speed feedback voltage
7 8 9 signal to selected voltage signal.
Stabilizer Z1 Positive (+) Wire 11 Thermistor RT
And Start Output Drive
Winding Terminal Assembly If unit overheats, PC1 disables unit
stopping all weld output.
Electrode
Contactor W 12 Gas Valve GS1
6 6
Controlled by circuitry on main
Burden Capacitor control board PC1. Allows shielding
Resistor Bank C5 gas to flow to the gun.
R1
8 Work 13 Wire Drive Motor PM

Negative (−) Feeds wire at speed set by R2.

Output 14 Gun Trigger Receptacle RC1
Terminal
Connects gun trigger circuit to
welding power source.
16 15 Receptacle RC2
Voltage Connects optional Spoolmate spool
Control R1 gun.
16 Voltage Control R1
17 Controls output voltage by providing
a reference voltage to the voltage
Wire Feed control circuit on PC1. Also, this
Speed Control control allows switching material
R2 thickness positions in Auto-Set
15
mode.
10-Pin Spool
Gun Receptacle 17 Wire Feed Speed Control R2
RC2 Controls wire feed motor speed by
providing a reference voltage to mo-
14 tor control circuit on PC1. Also, this
Gun Trigger control allows switching Auto-Set
Receptacle wire size positions.
RC1
18 Auto-Set Light LED2
18 Blue light is on when unit is operating
in Auto-Set mode.
Auto-Set Light
LED2 19 Thermal Overload Light LED1
When light is on it indicates that
thermistor RT1 has detected unit
19 overheating. For other diagnostic in-
Thermal formation on flashing LED (Eff
Overload w/MA440832N), see Section 7-2.
Light LED1
20 Power LED3
Lit when power is applied to unit. Fan
may not run at all times; use LED to
AC Or DC Control Circuits determine if unit has power applied.

1φ Power

Weld Current Circuit

Millermatic 212 Auto-Set TM-238119 Page 23

 B. Basic Training Circuit

TM-238119 Page 24 Millermatic 212 Auto-Set

 . This circuit is for training purposes only. It has been modified
for that use and may not reflect the actual circuit for your unit

Millermatic 212 Auto-Set TM-238119 Page 25

 SECTION 7 − TROUBLESHOOTING

7-1. Troubleshooting Flowchart

This flowchart is intended as a general guide only. Always read and follow the safety
information and specific instructions given elsewhere in this Technical Manual.

Note stock number and serial number of machine.

What does the operator say is wrong?
Gather Information What was the operator doing?
When and where does the problem occur?
Has any part of the system recently changed?

Check for signs of damage and for proper connections, gas

Visual Inspection supply, cable routing, consumables, and wire feed system.

For inverter power sources that have unknown problems or

Pre-Power Checks are not powering up.

Check for required input voltage, phases, and frequency.

Check Input Power Make sure power source and plugs are wired correctly. VAC
Make sure engine speed is set to correct RPM.

For important service memos and software updates.

Check Extranet It is possible the issue has already been identified and
addressed by Miller.

Check open-circuit voltage for each process and polarity.

Check OCV Check auxiliary power output if available.

Test machine under load with a load bank.

Load/Function Test Test all system functions.
Perform a weld test when possible.

Trouble1_2018-05

TM-238119 Page 26 Millermatic 212 Auto-Set

Notes

Millermatic 212 Auto-Set TM-238119 Page 27

7-2. Diagnostic Light (Eff w/MA440832N)
The Diagnostic light provides diagnostic modes to help troubleshoot various malfunctions with the unit.
Status Condition Error Remedy
Off Normal Unit is working properly. None
On Over Temperature Unit has overheated and output Release trigger and let unit cool
stopped. before continuing welding opera-
tion.
Flashing 1 Time Trigger Error Gun trigger is closed or shorted Release trigger, then pull trigger
when unit power is turned on. again to continue welding.
Spoolmatic 15/30A gun trigger
was held closed for more than 30
seconds without striking an arc.
Standard MIG gun trigger was
held closed for more than 120
seconds without striking an arc.
Flashing 2 Times Shorted Secondary Contact tip is directly shorted to Release trigger, move contact tip
the workpiece. Arc shuts off in off of workpiece and then pull
this condition. trigger again to continue welding.
Flashing 3 Times Motor Overcurrent Malfunction in wire drive system Release trigger, then pull trigger
or motor overcurrent again to continue welding.
Check for proper spool brake
adjustment or obstruction in the
gun liner and contact tip.

7-3. Troubleshooting Table

! Before connecting welding equipment to input (primary) power for servicing, be sure the input-power circuit protection is correct
for the welding equipment. Connect equipment to a dedicated circuit sized and fused for the rated output and duty cycle of the
welding equipment you are servicing. See the Electrical Service Guide section in this manual and National Electrical Code (NEC)
article 630, Electric Welders.
! Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine.

. Equipment serviced may need to meet additional requirements as specified in IEC60974−4, Arc Welding Equipment - Part 4: Periodic
Inspection and Testing.

. See Section 7-4 for test points and values and Section 10 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.
. See the Miller Extranet for service memos that may aid in the repair of this product.

Trouble Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13).

Replace building line fuse or reset circuit breaker if open (see Section 4-13).

Secure gun trigger connections (see welding gun Owner’s Manual).

Check continuity of Power switch S1, and replace if necessary.

Check stabilizer Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Over Temp light is on. Thermistor RT is detecting an overheating condition. Wait for unit to cool allowing
the fan to run. After unit is cool, If Over Temp light remains on, have Factory Authorized Service Agent
check for an open Thermistor RT (see Section 8-2).

No weld output; wire feeds. Connect work clamp to get good metal-to-metal contact.

Replace contact tip (see welding gun Owner’s Manual).

TM-238119 Page 28 Millermatic 212 Auto-Set

 Trouble Remedy
No weld output; wire feeds. Check main rectifier SR1, and replace if necessary.

Check stabilizer Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Over Temp light on. Unit has overheated and output stops. Let unit cool before continuing welding operation.

Over Temp light blinking. See Section 7-2.

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 4-13).

Check input voltage jumper links and correct position if necessary (see Section 4-11).

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Low, high, or erratic wire speed. Readjust front panel settings (see Section 5-1).

Change to correct size drive rolls (see Section 8-3).

Readjust drive roll pressure (see Section 4-14).

Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).

Check position of input voltage jumper links (see Section 4-11).

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Check hub tension setting (see Section 4-10).

No wire feed. Rotate Wire Speed control to higher setting (see Section 5-1).

Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual).

Readjust drive roll pressure (see Section 4-14).

Change to correct size drive rolls (see Section 8-3).

Rethread welding wire (see Section 4-14).

Check gun trigger and leads. Repair or replace gun if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T1 if necessary.

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Over Temp light is on. Thermistor RT is detecting an overheating condition. Wait for unit to cool allowing
the fan to run. After unit is cool, If Over Temp light remains on, have Factory Authorized Service Agent
check for an open Thermistor RT (see Section 8-2).

Improper or no gas flow. Clean or replace gas hose.

Clear blockage in gun.

If gas flow is excessive, replace regulator.

Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.

Check main control board PC1 and connections, and replace if necessary (see Section 7-8).

Fan motor FM not operating properly. Check and clear blocked fan blade.

Check coil voltage and connections of fan motor FM, and replace if necessary.

Millermatic 212 Auto-Set TM-238119 Page 29

7-4. Troubleshooting Circuit Diagram For Welding Power Source (Prior To MA440832N)

V1 V2 R2

R1 V2 R2

V4

V3

V3

V5

V6

Wire Drive V7
Motor M

Test Equipment Needed: See Section 7-8

For PC1 Data

TM-238119 Page 30 Millermatic 212 Auto-Set

 R3

V17
See Section 7-7
For Waveforms
A, B, C

V8

V9

V10

V11

V13

V14 V15

V16

238117-D

Millermatic 212 Auto-Set TM-238119 Page 31

7-5. Troubleshooting Circuit Diagram For Welding Power Source (Eff w/MA440832N)

V1 V2 R2
R1
V2 R2

V4

V3

V3

V5

V6

Wire Drive V7
Motor M

Test Equipment Needed: See Section 7-8

For PC1 Data

TM-238119 Page 32 Millermatic 212 Auto-Set

 R3

V17
See Section 7-7
For Waveforms
A, B, C

V8

V9

V10

V11

V12

V13

V14
V15

V16

248494-A

Millermatic 212 Auto-Set TM-238119 Page 33

7-6. Readings For Troubleshooting Circuit Diagram (All Models)
(Use With Section 7-5)
a) Tolerance +10% unless specified.
b) Reference − single arrow references to circuit common (lead 42),
double arrow reference to points indicated.
c) Turn Off unit and disconnect input power before checking resistance.

Voltage Readings

Designator Description Value Notes

V1 Input Power 230 volts AC with power switch S1 on.
V2 T1 Secondary SCR Voltage 25 volts AC with power switch S1 on.
V3 T1 Secondary Control Voltage. 24 volts AC with power switch S1 on.
PC1 Key Outputs
V4 Thermistor +1.5 volts to +4 volts DC varies with temperature.
V5 Gas Solenoid +35 volts DC with gun trigger closed.
V6 Weld Stabilizer Control Contactor +35 volts DC when contactor is energized on power up. Contac-
(W Coil) tor coil deenergizes when weld is established.
V7 Drive Motor +3 to 19 volts DC from min to max of wire feed speed command
with Mig gun trigger closed.
V8 Voltage Pot (S1) 0 to +5 volts DC from min to max.
V9 Wire Feed Pot (S2) 0 to +5 volts DC from min to max.
V10 LED 1, Thermal Overload +2.5 volts DC with LED 1 energized.
V11 LED 2, Autoset +2.5 volts DC with LED 2 energized.
V12* LED 3, Power +2.5 volts DC with LED 3 energized.
V13 Spool Gun Wire Feed Pot 0 to +5 volts DC from min to max of spool gun wire feed pot.
V14 Spool Gun Wire Feed Motor +5 to +21 volts DC from min to max of spool gun wire feed pot.
V15 Spool Gun Trigger +35 volts DC with spool gun trigger open, 0 volts with trigger
pressed.
V16 MIG Gun Trigger +35 volts DC with Mig gun trigger open, 0 volts with trigger
pressed.
V17 Unit Output +26 to +34 volts DC with with output on and min to max of R1.
Resistance Readings
R1 T1 Transformer (Primary) Less than 1 ohm
R2 T1 Transformer (Secondary) Less than 1 ohm
R3 Z1 Stabilizer Less than 1 ohm
*V12 not present on models before serial number MA440832N

TM-238119 Page 34 Millermatic 212 Auto-Set

7-7. Waveforms For Section 7-4
. The waveforms represent the output of the welding power source. When
operating properly, the power source waveforms match those shown here.

5 ms 10 V 5 ms 5 V

gnd gnd

B. 14.5 Volts DC, Voltage Control At Minimum,

A. 34 Volts DC Open-Circuit, 63 Amperes (Resistive Load)
Voltage Control At Maximum

5 ms 5 V 2 ms 2 V

gnd

gnd

C. Rated Voltage And Amperage, Voltage D. SCR Gate Pulses With Respect To
Control At Maximum, +24.5 Volts DC, Cathode At No Load (See Section 7-8)
160 Amperes (Resistive Load)

Test Equipment Needed:

Millermatic 212 Auto-Set TM-238119 Page 35

7-8. Main Control Board PC1 Testing Information (Use With Section 7-9)
Be sure plugs are secure before
testing. See Section 7-9 for specific
values during testing.
1 Main Control Board PC1
1 RC1

RC2

RC3

RC6

RC7
RC9

RC10 RC8

Test Equipment Needed:

260864 / 805249-A

TM-238119 Page 36 Millermatic 212 Auto-Set

7-9. Main Control Board PC1 Test Point Values

a) Tolerance − ±10% unless specified

PC1 Voltage Readings b) Reference − to circuit common
(lead 1) unless noted
c) Triggered − means gun trigger is
pressed
Receptacle Pin Values

RC1 1 Gate pulse to SCR module with respect to pin RC1-4 (see Section 7-7)

2 Gate pulse to SCR module with respect to pin RC1-3 (see Section 7-7)

3 SCR gate pulse return

4 SCR gate pulse return

RC2 1 Contactor, +35 volts DC with respect to pin RC2-7

2 Gas valve, +35 volts DC with respect to pin RC2-8

3 Drive motor, +3 to +19 volts DC (±3 volts dc) with respect to RC2-9

4 Current detect with respect to pin RC2-5 (arc voltage)

5 Feedback return

6 Voltage feedback, +14 to +38 volts DC with respect to pin RC2-5

7 Contactor return

8 Gas valve return

9 Drive motor return

10 Not used

11 Not used

12 Not used

RC3 1 MIG gun trigger in, +35 volts DC

2 MIG gun trigger in, return

3 Spool gun trigger in, +35 volts DC

4 Spool gun trigger return

5 Spool gun motor, +5 to +21 volts DC

6 Spool gun motor return

7 +5 volts DC with respect to pin RC3-9

8 0 to +5 volts DC from min to max with respect to pin RC3-9

9 Circuit common

Millermatic 212 Auto-Set TM-238119 Page 37

 Receptacle Pin Values
RC5 —— Factory use only

RC6 1 Thermal overload LED, +2.5 volts DC with respect to pin RC6-4

2 Prior to MA440832N: Not used. Eff w/MA440832N: Power LED3: +2.5 volts DC with respect to pin
RC6-3.

3 Prior to MA440832N: Not used. Eff w/MA440832N: Power LED3: +2.5 volts DC with respect to pin
RC6-2.

4 Thermal overload LED, +2.5 volts DC with respect to pin RC6-1

5 Auto-Set LED, +2.5 volts DC with respect to pin RC6-6

6 Auto-Set LED, +2.5 volts DC with respect to pin RC6-5

RC7 1 Fan control, 230 volts AC when fan is off with respect to pin RC7-2

2 Fan control, 230 volts AC when fan is off with respect to pin RC7-1

RC8 1 24 volts AC with respect to pin RC8-2

2 24 volts AC with respect to pin RC8-1

3 24 volts AC with respect to pin RC8-4

4 24 volts AC with respect to pin RC8-3

RC9 1 Thermistor input, +1.5 to 4 volts DC with respect to pin RC9-2 varies by temperature

2 Thermistor input, +1.5 to 4 volts DC with respect to pin RC9-1 varies by temperature

RC10 1 Voltage Pot (R1), 0 to +5 volts DC from min to max with respect to pin RC10-4

2 Wirefeed Pot (R2), 0 to +5 volts DC from min to max with respect to pin RC10-3

3 Wirefeed Pot Return (R2)

4 Voltage Pot Return (R1)

5 Voltage Pot (R1), +5 volts DC with respect to pin RC10-4

6 Wirefeed Pot (R2), +5 volts DC with respect to pin RC10-3

7 Not used

8 Not used

TM-238119 Page 38 Millermatic 212 Auto-Set

7-10. Checking Unit Output After Servicing
1 Weld Output Terminals
Check open-circuit voltage be-
tween terminals according to Sec-
tion 7-6.
If correct voltage is not present,
repeat troubleshooting procedures.

. Perform a load bank test to en-

sure welding generator oper-
ates properly after servicing.
Be sure load bank is capable of
handling the rated output of the
welding generator being tested
(see load bank Owner’s Manu-
al).
The load bank will simulate a
weld load and the electrical de-
1 mand on the unit. See Specifi-
cations section for rated load.
If unit does not perform at rated
load, repeat troubleshooting
procedures.
Complete pre-operational checks.
Reinstall cover and side panels.

Pre-Operational Checks
Check labels; replace labels that are unreadable or
damaged (see Parts List).
Clean weld output terminals. Tighten connections.
Clean outside of entire unit. Ref. Check Unit Static 2018-12 - 805249-A

Millermatic 212 Auto-Set TM-238119 Page 39

 SECTION 8 − MAINTENANCE

8-1. Routine Maintenance

! Disconnect power . Maintain more often

before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent

Every
3
Months

l Unreadable Labels ~ Weld Terminals nl Weld Cables

Every
6 OR
Months

~ Inside Unit n Apply Light Coat Of Oil

Or Grease To Drive Motor
Shaft

8-2. Unit Overload Protection And Tip Saver/Short Circuit Protection

A. Unit Overload Protection
Thermistor RT1 in rectifier SR1 protects the unit from damage due to overheating. If Over Temp light illuminates, output and wire feed will shut down.
Wait until Over Temp light turns off before resuming welding.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the
unit shuts down the welding output, but the fan continues to run. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the
workpiece, release gun trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue
operation.

8-3. Changing Drive Roll and Wire Inlet Guide

1 Securing Screw
2 Inlet Wire Guide
Loosen screw. Slide tip as close to
2 drive rolls as possible without
touching. Tighten screw.
3 Drive Roll

4 The drive roll consists of two

different sized grooves. The
stamped markings on the end
surface of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
motor shaft is the proper groove to
1 thread (see Section 4-14).
4 Drive Roll Securing Nut
Turn nut one click to secure drive
roll.

Tools Needed:
3
7/16 in.

Ref. 804914-A

TM-238 119 Page 40 Millermatic 212 Auto-Set

8-4. Aligning Drive Rolls and Wire Guide
! Turn Off power.
View is from top of drive rolls look-
ing down with pressure assembly
open.
Correct Incorrect 1 Drive Roll Securing Nut
3 4 2 Drive Roll
2 3 Wire Guide
1 4 Welding Wire
5 Drive Gear
5 Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Close pressure roll assembly.

Tools Needed:

Ref. 800412-A

Notes

Millermatic 212 Auto-Set TM-238119 Page 41

Notes

TM-238119 Page 42 Millermatic 212 Auto-Set

 SECTION 9 − ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Millermatic 212 Auto-Set Prior to MA440832N 238117-D ♦♦

MA440832N and following 248494-A Table 9-1

Circuit Board PC1 Prior to MA290011N 252091-A ♦♦ ♦♦

Eff w/MA290011N thru 245567-C ♦♦ ♦♦

MD182738N

MD182739N and following 260865-B ♦♦ ♦♦

♦♦ Not included in this manual

Millermatic 212 Auto-Set TM-238119 Page 43

 Figure 9-1. Circuit Diagram For Millermatic 212 Auto-Set Prior To MA440832N

TM-238119 Page 44 Millermatic 212 Auto-Set

 238117-D

Millermatic 212 Auto-Set TM-238119 Page 45

 Figure 9-2. Circuit Diagram For Millermatic 212 Auto-Set Eff w/ MA440832N And Following
TM-238119 Page 46 Millermatic 212 Auto-Set
 248494-A

Millermatic 212 Auto-Set TM-238119 Page 47

 Table 9-1. Lead List Summary For Millermatic 212 Auto-Set Models Eff w/LJ180755B And Following
. Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of conductive electric compound (Part No. 603978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−A NEGATIVE (−) OUTPUT STUD TO WORK CLAMP 0035A RC2 (E) TO PLG3 (7)
−−−− R3 TO C5 0036A RC2 (F) TO PLG3 (8)
−−−− DRIVE CASTING TO POSITIVE (+) OUTPUT STUD 0040A RC1 (1) TO PLG3 (1)
0002A POWER SWITCH INSIDE LEAD TO TE1 (2) 0043A C5 (NEG) TO RECTIFIER HEAT SINK
0003A FAN MOTOR TO TE1
0043B RECTIFIER HEAT SINK TO NEGATIVE (−) OUTPUT
0003A POWER SWITCH OUTSIDE LEAD TO TE1 (5)
0043D PLG2 (5) TO C5 (−)
0009A PLG2 (2) TO GS1
0044 W TO C5 (+)
0010A PLG2 (8) TO GS1
0044B SECONDARY CT XFMR TO C5 POSITIVE (+)
0013A PLG2 (1) TO W (COIL)
0044E PLG2 (6) TO W (TOP)
0016A PLG3 (5) TO RC2 (C)
0046A PLG2 (4) TO POSITIVE (+) OUTPUT STUD
0019A RC1 (2) TO PLG3 (2)
0047A RC2 (G) TO PLG3 (4)
0020A FAN MOTOR TO PLG7 (2)
0021A TE1 TO PLG7 (1) 0052A PLG3 (6) TO RC2 (B)

0030A PLG3 (9) TO RC2 (H) 0059A PLG2 (9) TO MOTOR PLUG (2)

0031A PLG2 (3) TO MOTOR PLUG (1) 0079A PLG2 (7) TO W (COIL)
0034A PLG3 (3) TO RC2 (D)

TM-238119 Page 48 Millermatic 212 Auto-Set

Notes
Notes
Notes
 Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2019 Miller Electric Mfg. LLC 2019−01