Related Manuals for Miller Millermatic 252
Summary of Contents for Miller Millermatic 252
- Page 1 OM-230 693L 2011−08 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 252 Visit our website at File: MIG (GMAW) www.MillerWelds.com...
- Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 7 − MAINTENANCE &TROUBLESHOOTING ......... . 7-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−01 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,... - Page 14 OM-230 693 Page 10...
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Page 15: Section 3 − Definitions
A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Do Not Switch Wire Feed Output Duty Cycle While Welding Volts Increase Gas Metal Arc Wire Feed Spool Welding (GMAW) Gas Input Gas Output Rated No-Load Voltage Input Press To Reset... -
Page 16: Welding Power Source Duty Cycle And Overheating
A complete Parts List is available at www.MillerWelds.com 4-2. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, Thermistor (RT1) opens, output stops, and cooling fan runs. -
Page 17: Section 5 − Installation
A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. 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. -
Page 18: Weld Output Terminals And Selecting Cable Sizes
**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. ( ) = mm 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 OM-230 693 Page 14... -
Page 19: Connecting To Weld Output Terminals
A complete Parts List is available at www.MillerWelds.com 5-4. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) 803 778-A Correct Installation Incorrect Installation Weld Output Terminal weld output terminal and secure with nut so Turn off power before connecting to that weld cable terminal is tight against... -
Page 20: Connecting Spoolmatic 15A Or 30A Gun
A complete Parts List is available at www.MillerWelds.com 5-6. Connecting Spoolmatic) 15A Or 30A Gun Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel. Positive Weld Output Terminal Connect weld cable to weld output terminal. -
Page 21: Connecting Xr Aluma-Pro, Xr Edge, Xr-A Gun, Or Xr-A Python
A complete Parts List is available at www.MillerWelds.com 5-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python XR Edge guns prior to serial no. LE079101 require an adapter cord (part no. 195 498). Gun End Gun Liner Wire Outlet Guide Trim excess liner from end of gun so no more than 3/32 in. -
Page 22: Setting Gun Polarity For Wire Type
A complete Parts List is available at www.MillerWelds.com 5-8. Setting Gun Polarity For Wire Type Changing Polarity Polarity Changeover Label Information Always read and follow manufacture’s recommended polarity. Wire Drive Work Clamp Lead Assembly Lead Positive Terminal Negative Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). -
Page 23: Installing Wire Spool And Adjusting Hub Tension
A complete Parts List is available at www.MillerWelds.com 5-10. Installing Wire Spool And Adjusting Hub Tension Use compression spring When a slight force is needed with 8 in. (200 mm) spools. to turn spool, tension is set. To install either a 1 lb or 2 lb wire Installing 1 Or 2 lb Wire Spool spool, follow the procedure as Spindle... -
Page 24: Electrical Service Guide
A complete Parts List is available at www.MillerWelds.com 5-12. 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) Input Amperes (A) At Rated Output... -
Page 25: Connecting Input Power
A complete Parts List is available at www.MillerWelds.com 5-13. Connecting Input Power =GND/PE Earth Ground 230 VAC, 1 804 912-A Receptacle Connect green or green/yellow grounding Installation must meet all National [NEMA Type 6-50R (Customer conductor to disconnect device grounding and Local Codes −... -
Page 26: Threading Welding Wire
A complete Parts List is available at www.MillerWelds.com 5-14. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. - Page 27 A complete Parts List is available at www.MillerWelds.com Notes OM-230 693 Page 23...
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Page 28: Weld Parameters
A complete Parts List is available at www.MillerWelds.com 5-15. Weld Parameters OM-230 693 Page 24... - Page 29 A complete Parts List is available at www.MillerWelds.com 226 650-B OM-230 693 Page 25...
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Page 30: Section 6 − Operation
A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Controls Voltage Control Turn control clockwise to increase voltage. Wire Speed Control Turn control clockwise to increase wire feed speed. Voltmeter Wire Feed Speed Meter This unit has three automatic timers included in its operation to help save contact tips, gas, and wire: Tip Saver −... - Page 31 A complete Parts List is available at www.MillerWelds.com JOG Mode MIG Gun Run−in is factory set at 100% To change Run−in settings, start with the which is recommended for most wire sizes power switch OFF. Press and hold the MIG and types.
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Page 32: Voltmeter And Wire Feed Speed Meter Operation
A complete Parts List is available at www.MillerWelds.com 6-2. Voltmeter And Wire Feed Speed Meter Operation Voltmeter Welding Status Gun Selection When either a MIG gun or spool gun trigger Wire Feed Speed Meter The wire feed speed meter will display is pressed and a welding arc is established, preset wire feed speed (IPM) for the the voltmeter displays actual weld voltage. -
Page 33: Timers
A complete Parts List is available at www.MillerWelds.com 6-4. Timers 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 Wire Speed Control range is from 25 to 150% of wire feed automatically. -
Page 34: Set Up Push Motor Torque (Sup) Or Reset (Res)
A complete Parts List is available at www.MillerWelds.com Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high. 6-5. Set Up Push Motor Torque (SUP) Or Reset (rES) Voltage Control The following items can be adjusted by over-torque limit and speed up the remote rotating the left knob counterclockwise wire feed speed motor. -
Page 35: Section 7 − Maintenance &Troubleshooting
A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels... -
Page 36: Aligning Drive Rolls And Wire Guide
A complete Parts List is available at www.MillerWelds.com 7-4. Aligning Drive Rolls and Wire Guide Turn Off power. View is from top of drive rolls looking down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw... -
Page 37: Troubleshooting
A complete Parts List is available at www.MillerWelds.com 7-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 5-13). Replace building line fuse or reset circuit breaker if open (see Section 5-13). Secure gun trigger connections (see welding gun Owner’s Manual). - Page 38 A complete Parts List is available at www.MillerWelds.com Trouble Remedy No wire feed. Turn Wire Speed control to higher setting (see Section 6-1). Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual). Readjust drive roll pressure (see Section 5-14). Change to correct size drive rolls (see Section 7-3).
- Page 39 A complete Parts List is available at www.MillerWelds.com Notes OM-230 693 Page 35...
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Page 40: Indicators
A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 36... - Page 41 A complete Parts List is available at www.MillerWelds.com HLP 4 HLP 8 All directions are in reference to the front of the unit. All circuitry referred to Indicates gun trigger was pulled and held for Indicates XR Edge gun trigger was pulled is located inside the unit.
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Page 42: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-230 693 Page 38... - Page 43 243 035-A OM-230 693 Page 39...
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Page 44: Section 9 − Mig Welding (Gmaw) Guidelines
SECTION 9 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 9-1. Typical MIG Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/... -
Page 45: Typical Mig Process Control Settings
9-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) -
Page 46: Holding And Positioning Welding Gun
9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece... -
Page 47: Conditions That Affect Weld Bead Shape
9-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Push Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long... -
Page 48: Gun Movement During Welding
9-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −... -
Page 49: Troubleshooting − Excessive Spatter
9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 50: Troubleshooting − Lack Of Penetration
9-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 51: Troubleshooting − Waviness Of Bead
9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. -
Page 52: Common Mig Shielding Gases
9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. - Page 53 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
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Page 54: Section 10 − Parts List
SECTION 10 − PARTS LIST 10-1. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires. - Page 55 Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
- Page 56 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co. 2011−01...