Miller Millermatic 252 User manual

Miller Millermatic 252 User manual
Millermatic 252
®
Quick
Specs
Industrial Applications
Processes
Metal Fabrication
Maintenance and Repair
Farm/Home
Light Industrial
MIG (GMAW)
Flux-Cored (FCAW)
Input Power
200(208)/230 V
230/460/575 V
Issued April 2013 • Index No. DC/12.49
MIG Arc Welding Power Source,
Wire Feeder and Gun Package
Rated Output
200 Amps at 28 VDC, 60% Duty Cycle
250 Amps at 28 VDC, 40% Duty Cycle
Max. Open-Circuit Voltage 38 V
Amperage Range 30 – 300 A
Wire Feed Speed 50 – 700 IPM (1.3 – 17.8 m/min.)
Weight 207 lb. (94 kg)
The Power of Blue .
®
Comes complete with:
15-ft. (4.6 m), 250-amp M-25 MIG gun
for .030/.035-in. wire
10-ft. (3 m) work cable with clamp
10-ft. (3 m) industrial power cord
(with plug on 200/230 V model)
Argon mix regulator/flow gauge and hose
Factory-installed running gear with
EZ-Change™ Low Cylinder Rack
.030/.035-in. reversible drive rolls
Extra contact tips
Set-up and operation CD
Highest output in its class (250 A at 28 VDC).
Weld longer on high-end applications.
Large, digital front panel with
built-in digital timers menu enables
operator to preset voltage and wire feed
speed. Standard run-in, pre/postflow,
burnback, spot/delay (stitch) timer menu.
Auto Gun Detect™ allows operator to
simply pull trigger on MIG gun, spool
gun or push/pull gun. Automatically
detects and recalls the voltage, wire
feed speed and timer of the active gun.
See page 3 for more information.
EZ-Access™ consumable compartment and
parameter chart. Set weld parameters right the
first time with convenient flip-down compartment
that provides fast access to parameter chart and
consumables. See page 3 for more information.
Push-pull gun direct connection.
Now directly connects your push-pull gun,
no extra module required.
Fan-On-Demand™
cooling system only
operates when needed,
reducing power
consumption and
contaminants drawn
into the machine.
Line voltage compensation keeps power
constant even if power input varies by
±10 percent.
Active Arc Stabilizer ™ minimizes weld
cleanup, and provides excellent starts
proven superior to the competition.
Welder is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Gun warranted for 90 days, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Website
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Specifications
Rated Output
200 A at 28 VDC,
60% Duty Cycle
(Subject to change without notice.)
Amperage
Range
Max.
OpenCircuit
Voltage
30 –300 A
38
Amps Input at Rated Output, 60 Hz
200(208) V 230 V 460 V 575 V KVA
48
2.3*
42
2*
21
1*
17
0.8*
KW
9.8 7.5
0.46* 0.13*
250 A at 28 VDC,
40% Duty Cycle
Wire Type and
Diameter
Wire Feed
Speed
Solid/Stainless
Steel
.023 – .045 in.
(0.6 – 1.2 mm)
50 –700 IPM
(1.3 – 17.8
m/min.)
Max.
Spool
Size
Dimensions
Net
Weight
12 in.
(305 mm)
H: 30 in.
(762 mm)
207 lb.
(94 kg)
W: 19 in.
(483 mm)
Flux-Cored
.030 – .045 in.
(0.8 – 1.2 mm)
D: 40 in.
(1016 mm)
*While idling.
Note: Operating Temperature Range: -4° to +104°F (-20° to +40°C). Storage Temperature Range: -22° to +122°F (-30° to +50°C).
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Control Panel
1
3
2
4
1. Voltmeter
2. Voltage Control
3. Wire Speed Meter
4. Wire Speed Control
Performance Data
VOLT/AMP CURVES
35
250
25
MAX
30
200
VOLTS
WELD AMPS
DUTY CYCLE CHART
500
450
400
350
300
150
100
20
MIN
15
10
5
50
10
0
20
30
40
% DUTY CYCLE
2
50
60
70
80 90 100
0
100
200
AMPERES
300
400
Standard Fully Loaded Features
EZ-Change™ Low Cylinder Rack
Operators no longer need to lift cylinders.
Cylinders now easily roll on and off our
EZ-Change™ Low Cylinder Rack.
Angled Wire Drive
Angled industrial aluminum dual-gear
drive system significantly improves wire
feeding and runs large spools of wire.
Allows quick change of drive rolls
without tools.
Drive roll storage — no more lost drive
rolls, extra drive rolls are conveniently
stored next to drive motor.
Operators no longer bump into and bend
MIG gun and gun liner.
Dual Front Handles
Split handle with rubber grips designed
to move machine easily and allow work
lead and MIG gun to be stored
independently.
Handles provide protection for front panel
and MIG gun during transportation.
EZ-Access™ Consumable
Compartment and Parameter Chart
Convenient flip-down compartment
holds parameter chart and storage for
consumables.
Auto-Gun Detect™
Simply pull the trigger for either the MIG,
spool gun or any Miller® push-pull gun.
The Millermatic 252 automatically recalls
voltage, wire feed speed and timer of the
active gun.
Reduces setup time!
3
Optional Fully Loaded Features
Elevated Gun and Cable Rack
#300 335
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
No more running over spool gun cables
or cables dragging on the floor.
Elevated Gun and Cable Rack can be
used with either a single or dual cylinder
rack. (Elevated Gun and Cable Rack is
included with the Dual EZ-Change™ Low
Cylinder Rack.)
Dual EZ-Change™ Cylinder Rack
with Elevated Gun and Cable Rack
#300 337
Dual cylinder rack allows for easy
storage for two cylinders.
EZ-Change™ Low Cylinder rack eliminates
the need to lift cylinders on and off
cylinder rack.
No more running over spool gun cables
or cables dragging on the floor.
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
4
Genuine Miller Accessories
®
Push-Pull Guns
Direct connection for Miller push-pull guns.
Able to utilize 12-inch rolls of aluminum
wire inside the Millermatic 252 for
extended aluminum welding time.
Wire feed speed is adjustable at the gun
and actual speed can be seen on the
digital display on the Millermatic 252.
Adjustable run-in control to fine tune
arc starting.
XR-Aluma-Pro™ Lite Push-Pull Gun
#300 948 25 ft. (7.6 m)
Air-cooled gooseneck-style gun for
.030–.047 in. (0.8–1.2 mm) aluminum.
Rated at 175 amps at 60 percent duty cycle.
M-25 Replacement Gun
#169 594 10 ft. (3 m)
#169 596 12 ft. (3.7 m)
#169 598 15 ft. (4.6 m) standard
Gun shipped to run .030 –.035 inch
(0.8 – 0.9 mm) wire.
Spoolmatic® 15A Spool Gun #195 156
Spoolmatic® 30A Spool Gun #130 831
Ideal for aluminum welding jobs. Air-cooled,
1-pound spool gun with 15-foot (4.6 m)
or 30-foot (9.1 m) cable assembly. Rated
at 200 amps at 100 percent duty cycle.
For detailed information, see Spoolmatic
literature, Index No. M/1.73.
Elevated Gun and Cable Rack #300 335
For use with single cylinder rack. (Included
with Dual EZ-Change Low Cylinder Rack.)
XR-Aluma-Pro™ Push-Pull Gun
#300 000 15 ft. (4.6 m)
#300 001 25 ft. (7.6 m)
Air-cooled gooseneck-style gun for
.030–.047 in. (0.8–1.2 mm) aluminum.
Rated at 200 amps at 100 percent duty cycle.
XR™-Pistol Push-Pull Gun
#198 127 15 ft. (4.6 m) cable
#198 128 30 ft. (9 m) cable
Air-cooled pistol grip gun for .030–.047 in.
(0.8–1.2 mm) aluminum. Rated at 200 amps
at 100 percent duty cycle.
U-Groove Aluminum Drive Roll and
Accessory Kits for Push-Pull Guns
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack #300 337
Dual cylinder rack allows operators to easily
roll cylinders on and off the rack with no
lifting. Gun and cable rack keeps cables off
the floor and tangle free.
Spoolmate™ 200 Spool Gun #300 497
Reliable and economical spool gun perfect
for hobbyists and light fabricators who
weld aluminum. Handles .030 –.035 inch
(0.8 – 0.9 mm) aluminum wires and
.023 –.035 inch (0.6 – 0.9 mm) steel/
stainless steel wires. Rated at 160 amps,
60 percent duty cycle with 20-foot cable
assembly. For detailed information, see
Spoolmate literature, Index No. M/1.47.
Protective Cover #195 142
Features side pocket.
(Not for use with Dual Cylinder Rack or
Elevated Gun and Cable Rack.)
Note: XR-Aluma-Pro kits include Millermatic U-groove
drive rolls, nylon wire guides and contact tips.
XR-Pistol kits include Millermatic U-groove drive rolls,
nylon wire guides, gun drive rolls and contact tips.
Argon/Mixed Gas Regulator and Gas Hose
#195 050
(Order from Miller Service Parts.)
For XR-Aluma-Pro (air-cooled)
#195 311 .035 in. (0.9 mm)
#195 312 .040 in. (1 mm)
#195 313 .047 in. (1.2 mm)
For XR Pistol (air-cooled)
#195 201 .035 in. (0.9 mm)
#195 273 .040 in. (1 mm)
#195 202 .047 in. (1.2 mm)
CO2 Regulator/Flow Gauge #237 702
Required if using 100 percent CO2 gas.
(Order from Miller Service Parts.)
5
Consumables
(Order from Miller Service Parts.)
Millermatic Drive Roll Kits
®
Note: Drive roll kits include two drive rolls and an
inlet guide.
V-Groove Drive Roll Kits (solid wire)
#204 579 .030 and .035 in.
(0.8 and 0.9 mm)
combination (reversible)
#087 131 .023/.025 in. (0.6 mm)
#079 594 .030 in. (0.8 mm)
#079 595 .035 in. (0.9 mm)
#079 596 .045 in. (1.2 mm)
Replacement Liners
#194 010 .023/.025 in.
#194 011 .030 –.035 in. (standard)
#194 012 .035 –.045 in.
M-Series Consumable Kits
#234 610 .030 in. (0.8 mm)
#234 611 .035 in. (0.9 mm)
#234 612 .045 in. (1.2 mm)
Contains ten contact tips, one nozzle, one
contact tip adapter and one nozzle adapter.
V-Knurled Drive Roll Kits
(flux-cored or difficult-to-feed wire)
#079 606 .035 in. (0.9 mm)
#079 607 .045 in. (1.2 mm)
U-Groove Drive Roll Kits
(aluminum wire)
#044 749 .035 in. (0.9 mm)
#079 599 .047 in. (1.2 mm)
For M-25 Gun
Contact Tips
#087 299 .023/.025 in. (0.6 mm)
#000 067 .030 in. (0.8 mm)
#000 068 .035 in. (0.9 mm)
#000 069 .045 in. (1.2 mm)
#187 117 .035 in. (0.9 mm) heavy-duty tip
#187 118 .045 in. (1.2 mm) heavy-duty tip
Tapered Contact Tips
#176 797 .030 in. (0.8 mm)
#176 793 .035 in. (0.9 mm)
#176 794 .045 in. (1.2 mm)
Nozzles
Note: Flush or stickout nozzles should be used for
the short-circuit process. Recessed nozzles should be
used for the spray arc process.
#200 258 Standard
1/2-inch (13 mm) diameter orifice. Nozzle
flush with contact tip.
#169 726
5/8-inch (16 mm) diameter orifice.
Nozzle flush with contact tip.
#169 727
5/8-inch (16 mm) diameter orifice. Contact
tip sticks out of nozzle 1/8 inch (3.2 mm).
#169 724
1/2-inch (13 mm) diameter orifice. Contact
tip recessed 1/8 inch (3.2 mm) into nozzle.
#169 725
5/8-inch (16 mm) diameter orifice. Contact
tip recessed 1/8 inch (3.2 mm) into nozzle.
Tapered Nozzles
Note: Tapered tips are recommended when using a
tapered nozzle.
Contact Tip Adapter #169 728
#176 243
3/8-inch (9.5 mm) diameter orifice.
#178 386
11/32-inch (8.7 mm) diameter orifice.
6
Ordering Information
Steel Configuration
Stock No.
Description
Millermatic® 252
#907 321
#907 322
200(208)/230 V, 60 Hz
230/460/575 V, 60 Hz
Millermatic V-Groove Drive Roll Kits (solid wire)
#087 131
#079 594
#079 595
#079 596
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.045 (1.2 mm)
Millermatic V-Knurled Drive Roll Kits (flux-cored)
#079 606
#079 607
.035 (0.9 mm)
.045 (1.2 mm)
Contact Tips (10 per package)
#087 299
#000 067
#000 068
#000 069
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.045 (1.2 mm)
Nozzles
#200 258
#169 726
#169 727
#169 724
#169 725
1/2-in. (13 mm) diameter, flush. Included with standard configuration
5/8-in. (16 mm) diameter, flush
5/8-in. (16 mm) diameter, 1/8-in. (3.2 mm) exposed
1/2-in. (13 mm) diameter, 1/8-in. (3.2 mm) recessed
5/8-in. (16 mm) diameter, 1/8-in. (3.2 mm) recessed
M-Series Gun Consumable Kits (for M-25)
#234 610
#234 611
#234 612
.030 in. (0.8 mm)
.035 in. (0.9 mm)
.045 in. (1.2 mm)
Aluminum Configuration (Spool Gun)
Qty.
For M-25 gun consumables and non-aluminum Millermatic 252 drive rolls, see steel configuration chart above.
Millermatic 252 Spool Gun Packages
(includes standard M-25 MIG gun)
#951 066
200(208)/230 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
elevated gun and cable rack, regulator and hose
#951 065
230/460/575 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
elevated gun and cable rack, regulator and hose
Spoolmatic Contact Tips (10 per package)
#206 187
#206 188
#206 189
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
Spoolmatic Nozzles
#198 855
#199 618
#199 616
#199 617
5/8-in. (16 mm) diameter
5/8-in. (16 mm) diameter, HD
3/4-in. (19 mm) diameter
3/4-in. (19 mm) diameter, HD
®
Aluminum Configuration (Push-Pull Guns)
For M-25 gun consumables and non-aluminum Millermatic 252 drive rolls, see steel configuration chart above.
Millermatic® 252
(includes standard M-25 MIG gun)
#907 321
#907 322
200(208)/230 V, 60 Hz
230/460/575 V, 60 Hz
XR-Aluma-Pro™ Lite Gun (air-cooled)
#300 948
25 ft. (7.6 m)
XR-Aluma-Pro™ Gun (air-cooled)
#300 000
#300 001
15 ft. (4.6 m)
25 ft. (7.6 m)
XR™-Pistol (air-cooled)
#198 127
#198 128
15 ft. (4.6 m)
30 ft. (9.1 m)
Millermatic U-Groove Drive Roll Kits (aluminum)
#044 749
#079 599
.035 (0.9 mm)
.047 (1.2 mm)
XR-Aluma-Pro™ U-Groove Drive Roll Kits
(required, includes Millermatic U-Groove Drive Roll Kit)
#195 311
#195 312
#195 313
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
XR™-Pistol U-Groove Drive Roll Kits
(required, includes Millermatic U-Groove Drive Roll Kit)
#195 201
#195 273
#195 202
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
XR-Aluma-Pro™ Lite Contact Tips (10 per package)
T-035AL
T-047AL
.035 (0.9 mm)
.047 (1.2 mm)
XR-Aluma-Pro™ and XR™-Pistol
Contact Tips (10 per package)
#206 187
#206 188
#206 189
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
Nozzles
#198 855
#199 618
#199 616
#199 617
5/8-in. (16 mm) diameter
5/8-in. (16 mm) diameter, HD
3/4-in. (19 mm) diameter
3/4-in. (19 mm) diameter, HD
Date:
Price
Total Quoted Price:
7
Ordering Information
Accessories
Stock No.
Description
XR-Aluma-Pro Lite Gun (air-cooled)
#300 948
25 ft. (7.6 m)
XR-Aluma-Pro™ Gun (air-cooled)
#300 000
#300 001
15 ft. (4.6 m)
25 ft. (7.6 m)
XR™-Pistol Gun (air-cooled)
#198 127
#198 128
15 ft. (4.6 m)
30 ft. (9 m)
M-25 Gun
#169 594
#169 596
#169 598
10 ft. (3 m), .023 –.035 in. (0.6 – 0.9 mm)
12 ft. (3.7 m), .023 –.035 in. (0.6 – 0.9 mm)
15 ft. (4.6 m), .023 –.035 in. (0.6 – 0.9 mm)
Spoolmatic® 15A
#195 156
15 ft. (4.6 m), 200 A, .023–1/16 in. (0.6–1.6 mm) for aluminum
Spoolmatic® 30A
#130 831
30 ft. (9 m), 200 A, .023–1/16 in. (0.6–1.6 mm) for aluminum
Spoolmate™ 200
#300 497
20 ft. (6 m), 160 A, .030 –.035 in. (0.8– 0.9 mm) for aluminum,
.023 –.035 in (0.6– 0.9 mm) for steel/stainless steel wires
Optional Spoolmate 200 Barrel Assemblies
#300 591
#300 592
#300 593
45-degree barrel
9-in. extension barrel
Heavy-duty barrel
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack
#300 337
Elevated Gun and Cable Rack
#300 335
For use with single cylinder rack.
(Included with Dual EZ-Change Low Cylinder Rack.)
Protective Cover
#195 142
Features side pocket
Argon/Mixed Gas Regulator and Gas Hose
#195 050
CO2 Regulator/Flow Gauge
#237 702
™
Date:
Qty.
Required if using 100% CO2 gas. (Order from Miller Service Parts.)
Total Quoted Price:
Note: See page 7 for ordering information on the Millermatic 252 — available packages, steel and aluminum configurations, and drive roll kits/consumables.
Distributed by:
Litho in USA
Price
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