Professional Documents
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Description
Millermatic 252
R
The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
Only qualified persons should test, maintain, and repair this D Be careful not to short metal tools, parts, or
unit. wires together during testing and servicing.
D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
D Have only qualified persons remove doors, D Have only qualified persons familiar with
panels, covers, or guards for maintenance and electronic equipment install, test, and service
troubleshooting as necessary. H.F. producing units.
D Keep hands, hair, loose clothing, and tools D The user is responsible for having a qualified electrician prompt-
away from moving parts. ly correct any interference problem resulting from the installa-
D Reinstall doors, panels, covers, or guards tion.
when maintenance is finished and before re- D If notified by the FCC about interference, stop using the
connecting input power. equipment at once.
D Have the installation regularly checked and maintained.
ELECTRIC AND MAGNETIC FIELDS (EMF) D Keep high-frequency source doors and panels tightly shut, keep
can affect Implanted Medical Devices. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the READ INSTRUCTIONS.
device manufacturer.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
OVERUSE can cause OVERHEATING. D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully be-
D Allow cooling period; follow rated duty cycle.
fore installing, operating, or servicing unit. Read the safety in-
D Reduce current or reduce duty cycle before formation at the beginning of the manual and in each section.
starting to weld again. D Perform maintenance and service according to the Technical
D Do not block or filter airflow to unit. Manual, industry standards, and national, state, and local codes.
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
SECTION 3 − SPECIFICATIONS
3-1. Specifications
Max. Open Amps Input at Rated Output (60% Duty Cycle), 60 Hz, Single-Phase
Rated Output Circuit
Voltage 200 (208) V 230 V 400 V 460 V 575 V KVA KW
250 A at 28 VDC, 200 A at 28 VDC, 38 48 46 24 23 18 9.8 7.5
40% Duty Cycle 60% Duty Cycle 2.3* 2* 1.2* 1* 0.8* 0.46* 0.13*
Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Without Gun
Solid Steel Stainless Steel Flux Cored 50−700 IPM H: 30 in. (762 mm) 205 lb
(1.3−17.8 m/min) W: 19 in. (483 mm) (93 kg)
.023 − .045 in. .023 − .045 in. .030 − .045 in. D: 40 in. (1016 mm)
(0.6 − 1.2 mm) (0.6 − 1.2 mm) (0.8 − 1.2 mm)
* While idling
Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C
100
50
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
60% Duty Cycle At 200 Amperes 40% Duty Cycle At 250 Amperes
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
20 Volt min
Volt max
15
10
0
0 50 100 150 200 250 300 350
Amperes
ssb1.1 10/91 − 239 342
Location
18 in.
(460 mm)
18 in.
(460 mm)
loc_2 3/96 - Ref. 804 912-A
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
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)
Positive Negative
(+) (−) 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)
804 909-A
* 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, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08
4
1
Do not place
anything between
weld cable terminal
and copper bar.
3
Tools Needed:
3/4 in. (19 mm)
803 778-A
Correct Installation Incorrect Installation
! Turn off power before connecting to 1 Weld Output Terminal output terminal and secure with nut so that
weld output terminals. 2 Supplied Weld Output Terminal Nut weld cable terminal is tight against copper
3 Weld Cable Terminal bar. Do not place anything between weld
! Failure to properly connect weld cable terminal and copper bar. Make
cables may cause excessive heat 4 Copper Bar
sure that the surfaces of the weld cable
and start a fire, or damage your ma- Remove supplied nut from weld output ter- terminal and copper bar are clean.
chine. minal. Slide weld cable terminal onto weld
Tools Needed:
3/4 in.
804 909-A
Tools Needed:
3/4, 5/8 in.
804 910-A
Changing Polarity
1 Polarity Changeover Label
Information
Always read and follow manufacture’s
recommended polarity.
D
D
Tools Needed:
1-1/8, 5/8 in.
802 028-A / Ref. 804 912-A
Remove these
components
from spindle.
Tools Needed:
15/16 in.
072573-B / 802 922
60 Hz Single Phase
Input Voltage (V) 200 230 400 460 575
Input Amperes (A) At Rated Output 48 46 24 23 18
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 60 50 30 25 20
Normal Operating Fuses 3 70 60 35 30 25
Min Input Conductor Size In AWG 4 8 8 12 12 14
96 127 156 206 209
Max Recommended Input Conductor Length In Feet (Meters)
(29) (39) (47) (63) (64)
Min Grounding Conductor Size In AWG 4 8 10 12 12 14
Elec Serv 2011−04
L1 7
8 L2
3 1
L2 L1
230 VAC, 1
804 912-A
! Installation must meet all National 2 Receptacle Connect green or green/yellow grounding
and Local Codes − have only qualified [NEMA Type 6-50R (Customer conductor to disconnect device grounding
persons make this installation. Supplied)] terminal first.
3 Input Power Cord. Connect input conductors L1 and L2 to
! Disconnect and lockout/tagout input disconnect device line terminals.
power before connecting input con- Connect directly to line disconnect device if
ductors from unit. hard wiring is required. 9 Over-Current Protection
4 Disconnect Device (switch shown in Select type and size of over-current
! Always connect green or green/yel- the OFF position) protection using Section 4-12 (fused
low conductor to supply grounding 5 Disconnect Device Grounding Terminal disconnect switch shown).
terminal first, and never to a line ter-
minal. 6 Disconnect Device Line Terminals Connect plug to receptacle if hard wiring
7 Black And White Input Conductor (L1 method is not used.
See rating label on unit and check input volt- And L2)
age available at site. Close and secure door on disconnect device.
8 Green Or Green/Yellow Grounding Remove lockout/tagout device, and place
1 Plug (NEMA Type 6-50P) Conductor switch in the On position.
1 2 Tools Needed:
3
5 6
6 in.
(150 mm)
Open pressure assembly. Pull and hold wire; cut off end.
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. 802 064-D / S-0627-A
3 4
1 2
. This unit has three automatic timers included in its operation to help save con-
tact tips, gas, and wire:
Tip Saver − Weld output shuts off if tip is shorted to work surface.
Safety shut-off − Weld output will shut off if no arc is detected within 3 seconds after
gun trigger is depressed.
Jog mode − When loading a new roll of wire or if the gun trigger is accidentally
pressed, gas will shut off after 1 minute and wire will shut off after 2 minutes saving
wire and gas.
226 647-B
1 2
3 4
1 2
1 Voltage Control Run-in speed (run) − The speed of the wire Spot Timer (SPO) − The amount of time
prior to the welding arc being struck. The that the arc will be active before it shuts off
2 Wire Speed Control
range is from 25 to 150% of wire feed automatically. The range is from 0 to 120
3 Voltmeter speed(WFS). seconds. Spot timer is reset upon release
Preflow (PrE) − The amount of time that of welding gun trigger.
4 Wire Feed Speed Meter
the shielding gas will flow after the trigger “Stitch” Timer (dLY) − Used in
To enter the TIMERS menu press and hold is depressed and before the welding arc conjunction with the Spot timer and while
the gun trigger while turning on the power will be allowed to be active. The range is the trigger is continuously depressed.
switch until the left meter displays (run), from 0.0 to 5.0 seconds. Controls the amount of time that the arc will
then release trigger. Postflow (POS) − The amount of time that be inactive after the Spot timer times out.
the shielding gas will flow after the arc has The range is from 0 to 120 seconds.
Once in the TIMERS menu, rotate the left
been shut off. The range is from 0.0 to 10.0
knob clockwise (CW) to find the particular To save settings and exit the TIMERS
seconds.
item, and rotate the right knob to change menu, depress the gun trigger.
the setting. Burnback (Bur) − The amount of time that
the welding wire remains electrically ener-
The following items can be adjusted by gized after the wire feeding has stopped.
rotating the left knob clockwise (CW): The range is from 0.01 to 0.25 seconds.
3 4
1 2
Contactor W
13
10-Pin Spool
Gun And
Push/Pull
Receptacle
RC7
14
Gun Trigger
Receptacle
RC1
AC Or DC Control Circuits
1φ Power
drawing #
! 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 weld-
ing equipment you are servicing. See the Electrical Service Guide section in this manual and National Electrical Code (NEC) article
630, Electric Welders.
. Equipment serviced may need to meet additional requirements as specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic Inspec-
tion and Testing.
. See Section 7-3 for test points and values, and Section 10 and following 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).
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 7-5).
HL.P 002 appears on meters. Thermistor RT1 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, check for an open Thermistor RT1
(see Section 8-2).
HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
short circuit (see Section 7-2) . If message remains, check for shorted trigger leads.
run appears on meters during power up. Check for shorted contacts in the Reed Relay.
No weld output; wire feeds. Thermistor RT1 detecting overheating condition. Allow fan to run; the thermistor will reset unit when
cooled (see Section 8-2).
HL.P 003 appears on meters, check main control board and main rectifier.
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 7-5).
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 7-5).
Low, high, or erratic wire speed. Readjust front panel settings (see Section 5-1).
Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).
Check main control board PC1 and connections, and replace if necessary (see Section 7-5).
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).
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 7-5).
H002 message appears on displays to indicate thermistor RT detected unit is in an overheated condition
(see Section 8-2).
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 7-5).
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.
V A V A
HLP 1 HLP 7
V A V A
HLP 2 HLP 8
V A V A
HLP 3 HLP 9
V A V A
HLP 4 HLP 10
V A V A
HLP 5 HLP 11
V A V A
HLP 6 HLP 12
SC-187 212-A
R1 R2
V2
V3 Waveform G
V1
V4
V5
V6
V8
Voltage Readings:
a) Tolerance − ±10% unless specified
b) Reference − to circuit common (lead 1)
unless noted
c) Wiring Diagram − see Section 9
V1 230 volts AC with fan energized
V2, 28 volts AC with Power switch
R3 V3 S1 On
V4, 24 volts AC with Power switch
V5 S1 On
V10
A, B, C, V6* +35 volts DC with gun trigger pressed
D, E, F V7 varies with temperature from +1.5 to +4 volts DC
V8 +35 volts DC with contactor energized
See Section 7-4
For Waveforms V9 +35 volts DC ±1 V to gun circuit with gun trigger off
A, B, C, D, E, F V10 +28 to +38 volts DC from min to
max of voltage command signal
V11* +6 volts DC ±4 V to +24 volts DC ±3 V from min to
max of IPM command signal with gun trigger
pressed
*Not present when triggered from optional spool gun
connected to receptacle RC7.
V7
V9
Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
R2 Less than 1 ohm
R3 Less than 1 ohm with contactor closed
243 035-A
gnd gnd
5 ms 10 V 5 ms 5 V
gnd
gnd
gnd
gnd
2 ms 2V
gnd
Factory
6 use only
5
7 8
RC1 1 Gate pulse to SCR module with respect to pin RC1-4 (see Section 7-4)
2 Gate pulse to SCR module with respect to pin RC1-3 (see Section 7-4)
RC2 1 Voltage feedback +28 to +38 volts DC with respect to pin RC2-2
5 Drive motor +6 to +24 volts DC (±3 volts DC) with respect to RC2-9
7 Contactor return
10 No testing required
11 No testing required
12 No testing required
13 No testing required
14 No testing required
2 Transmit to PC2
4 Ground to PC2
5 Ground to PC2
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
2 Spool gun or push/pull gun potentiometer command 0 to +5 volts DC with respect to pin RC2-3
3 Spool gun or push/pull gun potentiometer +5 volts DC reference with respect to pin RC2-2
Check labels; replace labels that are unreadable or damaged (see Parts List). n Complete pre-operational checks in
table. Reinstall wrapper, side panel,
Clean outside of entire unit. n and door.
3/4 in.
3/8 in.
Every
3
Months
Tools Needed:
7/16 in
Ref. 804 914-A
Tools Needed:
. 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.
0022 PLG6 (4) TO PLG12 (4) 0061 PLG6 (1) TO PLG12 (1)
0030A PLG13 (1) TO RC2 (H) 0068A PLG13 (4) TO RC2 (J)
0031A PLG5 (5) TO MOTOR PLUG (1) 0079A PLG5 (7) TO W (COIL)
0034A PLG3 (3) TO RC2 (D) JUMPA JUMPER
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Millermatic 252
R
7
12 16
10 15
11 14
13
6
17
3 − Figure 10-4
21 20
23
1 − Figure 10-2
19 − Figure 10-3
22
18
804 915-A
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Millermatic 252 TM-230 694 Page 57
. Hardware is common and
not available unless listed.
13
14
12
11
10
15
9
16
17
18
8 19
3
26
20
2
25
7
6
5
22
4
1 24
23
21 − Figure 10-5
804 916-B
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
3
7
2
8
9
15
14
10
11
13
17
12
16
804 917-A
12
8
7
6
13
4 5 14
804 918-A
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Millermatic 252 TM-230 694 Page 61
See Section 10-1 10
Drive Roll & Wire Guide Kits.
9 11
. Hardware is common and
not available unless listed.
8
7 12
14 13
18
5
4
16 15
3
2
1
24
17 20
19
23 21
25 22 804 919-B
Figure 10-5. Wire Drive And Gears
Item Dia. Part
No. Mkgs. No. Description Quantity
.030 in. .030 in. 0.8 mm 079 594 053 695 V-Grooved 056 192
.035 in. .035 in. 0.9 mm 079 595 053 700 V-Grooved 056 192
.045 in. .045 in. 1.2 mm 079 596 053 697 V-Grooved 056 193
Ref. S-0026-B/7-91
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2014 Miller Electric Mfg. Co. 2014−01