Miller Electric Millermatic 252 Owner'S Manual Download Page 1

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Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source

and Wire Feeder

OM-230 693C

2007−11

Millermatic 252

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

Summary of Contents for Millermatic 252

Page 1: ...Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source and Wire Feeder OM 230 693C 2007 11 Millermatic 252 R File MIG GMAW Visit our website at www MillerWelds com...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...nd Overheating 12 4 3 Volt Ampere Curves 12 4 4 Connecting To Weld Output Terminals 13 4 5 Installing Work Cable And Clamp 13 4 6 Connecting Spoolmatic 15A Or 30A Gun 14 4 7 Connecting XR Aluma Pro XR...

Page 4: ...ics 40 8 7 Good Weld Bead Characteristics 40 8 8 Troubleshooting Excessive Spatter 41 8 9 Troubleshooting Porosity 41 8 10 Troubleshooting Excessive Penetration 41 8 11 Troubleshooting Lack Of Penetra...

Page 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Page 6: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Page 7: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Page 8: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 10: ...de protection Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La proj...

Page 11: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Page 12: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Page 13: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Page 14: ...OM 230 693 Page 10...

Page 15: ...Input at Rated Output 60 Duty Cycle 60 Hz Single Phase Rated Output Max OpenCircuit Voltage 200 208 V 230 V 460 V 575 V KVA KW 250 A at 28 VDC 40 Duty Cycle 200 A at 28 VDC 60 Duty Cycle 38 48 2 3 42...

Page 16: ...duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 150 215 A 40 Duty Cycle At 250 Amperes 60 Duty...

Page 17: ...erminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfac...

Page 18: ...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 reg...

Page 19: ...3 32 in 2 4 mm of liner extends past wire outlet guide 4 Gun Securing Knob Loosen securing knob Insert gun end through opening until it bottoms against drive assembly make sure gun end does not touch...

Page 20: ...ools Needed Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open...

Page 21: ...low the procedure as shown in the illustration Remove these components from spindle Spindle Spindle Install these components onto spindle Order extra spring Part No 186 437 4 11 Positioning Jumper Lin...

Page 22: ...onductor Size In AWG4 8 8 12 14 Max Recommended Input Conductor Length In Feet Meters 96 29 127 39 206 63 209 64 Min Grounding Conductor Size In AWG4 8 10 12 14 Reference 2005 National Electrical Code...

Page 23: ...t 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 Black And White Input Con...

Page 24: ...ressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Pr...

Page 25: ...A complete Parts List is available at www MillerWelds com OM 230 693 Page 21 Notes...

Page 26: ...A complete Parts List is available at www MillerWelds com OM 230 693 Page 22 4 15 Weld Parameters...

Page 27: ...A complete Parts List is available at www MillerWelds com OM 230 693 Page 23 226 650 B...

Page 28: ...Speed Meter 2 3 This unit has three automatic timers included in its operation to help save contact tips gas and wire Tip Saver Weld output shuts off if tip is shorted to work surface Safety shut off...

Page 29: ...ttings start with the power switch OFF Press and hold the MIG or Spool Gun Trigger while turning the power switch ON The unit will power up with both the displays reading 888 then the voltage display...

Page 30: ...ed speed meter always displays preset wire feed speed IPM Gun Selection The wire feed speed meter will display preset wire feed speed IPM for the appropriate gun selection either MIG Spool or Push Pul...

Page 31: ...after the trigger is depressed and before the welding arc will be allowed to be active The range is from 0 0 to 5 0 seconds Postflow POS The amount of time that the shielding gas will flow after the...

Page 32: ...g items can be adjusted by rotating the left knob counterclockwise CCW Set up Push Motor Torque SUP This feature is only active when a push pull gun is connected to the welding power source The SUP se...

Page 33: ...g If HL P 002 is displayed on the meters wait for unit to cool allowing fan motor to run before trying to weld If unit is cool and no weld output continues contact Factory Authorized Service Agent 6 3...

Page 34: ...r View is from top of drive rolls looking down with pressure assembly open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out u...

Page 35: ...k for shorted trigger leads Have Factory Authorized Service Agent check Power switch Have Factory Authorized Service Agent check all board connections and main control board No Weld Output wire feeds...

Page 36: ...T is detecting an overheating condition Wait for unit to cool allowing the fan to run After unit is cool If HL P 002 message remains contact Factory Authorized Service Agent see Section 6 2 HL P 004...

Page 37: ...OM 230 693 Page 33 Notes...

Page 38: ...OM 230 693 Page 34 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 39: ...OM 230 693 Page 35 229 485 A...

Page 40: ...nnections 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 Wire Feeder Power Source Wor...

Page 41: ...in 035 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 25...

Page 42: ...in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle...

Page 43: ...electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSI...

Page 44: ...t Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slig...

Page 45: ...Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place no...

Page 46: ...on Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pa...

Page 47: ...upport 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 Base metal moves in the direction of th...

Page 48: ...aged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire...

Page 49: ...ecessary 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 welding power source Readjust welding parameter...

Page 50: ...shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Ref S 0026 B 7 91 Wire Diameter Fraction Decimal Metric 023 02...

Page 51: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 52: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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