TM-230694U 2018−09

Eff. w/Serial Number LG290851B And

Following
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source

and Wire Feeder

Millermatic 252
R

For product information, File: MIG (GMAW)

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 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. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Welding Power Source Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-3. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-4. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-5. Installing Work Cable And Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-6. Connecting Spoolmatic® 15A Or 30A Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-8. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-9. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-10. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-11. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-13. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-14. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-15. Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-2. Voltmeter And Wire Feed Speed Meter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-3. Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-4. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-5. Set Up Push Motor Torque (SUP) Or Reset (rES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 6 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-2. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-3. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-4. Readings For Troubleshooting Circuit Diagram (All Mode Use With Section 7-3) . . . . . . . . . . . . . . . . 32
7-5. Waveforms For Section 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-6. Main Control Board PC1 Testing Information (Use With Section 7-7) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-7. Main Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-8. User Interface Board PC2 Testing Information (Use With Section 7-9) . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-9. User Interface Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-10. Pre-Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-2. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-3. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-4. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
 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 OM-230693-M, safety_stm 2018-01

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.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manual ARC FLASH can kill.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Arc flash is the rapid and violent release of energy that
to avoid the hazard. occurs when electric current leaves its intended path
and arcs to other conductors or to ground. Arc flash
Only qualified persons should install, operate, maintain, and can be caused by equipment failure (faulty insulation,
corrosion, dust) improper installation, human error (improper tool
repair this equipment. A qualified person is defined as one placement), and other factors. Conductive vapors can sustain the
who, by possession of a recognized degree, certificate, or arc until over-current devices open the circuit. Individuals within
professional standing, or who by extensive knowledge, train- the arc flash boundary are at risk.
ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the D Do not work on energized equipment unless an assessment of
work, or the project and has received safety training to recog- arc flash risk from the electrical supply circuit has been conducted
nize and avoid the hazards involved. 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
During servicing, keep everybody, especially children, away. Personal Protective Equipment (PPE).

ELECTRIC SHOCK can kill. STATIC (ESD) can damage PC boards.

D Do not touch live electrical parts. D Put on grounded wrist strap BEFORE handling
boards or parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using D Use proper static-proof bags and boxes to
line disconnect switch, circuit breakers, or by removing plug from re- store, move, or ship PC boards.
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit. FIRE OR EXPLOSION hazard.
D Do not work on equipment unless it has been verified that the ma- D Do not place unit on, over, or near combustible
chine case is not energized. surfaces.
D Insulate yourself from ground by standing or working on dry insulat- D Do not service unit near flammables.
ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended. FLYING METAL or DIRT can injure eyes.
D If this procedure requires an energized unit, have only personnel D Wear safety glasses with side shields or face
familiar with and following standard safety practices do the job. shield during servicing.
D When testing a live unit, use the one-hand method. Do not put both D Be careful not to short metal tools, parts, or
hands inside unit. Keep one hand free. wires together during testing and servicing.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source. HOT PARTS can burn.

SIGNIFICANT DC VOLTAGE exists in inverter weld- D Do not touch hot parts bare handed.
ing power sources AFTER removal of input power. D Allow cooling period before working on
equipment.

D Turn off unit, disconnect input power, and discharge input capaci- D To handle hot parts, use proper tools and/or wear heavy, insu-
tors according to instructions in Manual before touching any parts. lated welding gloves and clothing to prevent burns.

Millermatic 252 TM-230694 Page 1

 EXPLODING PARTS can injure. ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Failed parts can explode or cause other parts to
D Wearers of Pacemakers and other Implanted
explode when power is applied to inverters.
Medical Devices should keep away from serv-
D Always wear a face shield and long sleeves icing areas until consulting their doctor and the
when servicing inverters. device manufacturer.

OVERUSE can cause OVERHEATING.

SHOCK HAZARD from testing.
D Allow cooling period; follow rated duty cycle.
D Turn Off welding power source and wire feeder D Reduce current or reduce duty cycle before
or stop engine before making or changing me- starting to weld again.
ter lead connections.
D Do not block or filter airflow to unit.
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.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
FALLING EQUIPMENT can injure. communications equipment.
D Have only qualified persons familiar with electronic equipment
D Use lifting eye to lift unit only, NOT running
install, test, and service H.F. producing units.
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of ade- D The user is responsible for having a qualified electrician prompt-
quate capacity to lift and support unit. ly correct any interference problem resulting from the installa-
tion.
D If using lift forks to move unit, be sure forks are long enough to D If notified by the FCC about interference, stop using the
extend beyond opposite side of unit. equipment at once.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu- D Have the installation regularly checked and maintained.
ally lifting heavy parts or equipment. 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.
MOVING PARTS can injure.
READ INSTRUCTIONS.
D Keep away from moving parts such as fans.
D Keep away from pinch points such as drive D Use Testing Booklet (Part No. 150 853) when
rolls. servicing this unit.
D Have only qualified persons remove doors, D Consult the Owner’s Manual for welding safety
panels, covers, or guards for maintenance and precautions.
troubleshooting as necessary. D Use only genuine replacement parts from the manufacturer.
D Keep hands, hair, loose clothing, and tools D Read and follow all labels and the Technical Manual carefully be-
away from moving parts. fore installing, operating, or servicing unit. Read the safety in-
formation at the beginning of the manual and in each section.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before re- D Perform installation, maintenance, and service according to the
connecting input power. Technical Manual, industry standards, and national, state, and
local codes.

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 3. Do not coil or drape cables around your body.
and magnetic fields (EMF). The current from arc welding (and allied pro- 4. Keep head and trunk as far away from the equipment in the
cesses including spot welding, gouging, plasma arc cutting, and welding circuit as possible.
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace- 5. Connect work clamp to workpiece as close to the weld as
makers. Protective measures for persons wearing medical implants possible.
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
7. Do not weld whilst carrying the welding power source or wire
following procedures in order to minimize exposure to EMF fields from
feeder.
the welding circuit:
About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a Implanted Medical Device wearers should consult their doctor and the
cable cover. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
2. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom-
to one side and away from the operator. mended.
TM-230694 Page 2 Millermatic 252
 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. 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

Millermatic 252 TM-230 694 Page 3

3-2. Welding Power Source Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
500 load without overheating.
450 If unit overheats, Thermistor (RT1)
400
opens, output stops, and cooling
350
fan runs. Wait fifteen minutes for
WELD AMPERES 300 unit to cool. Reduce amperage or
250 voltage, or duty cycle before
welding.
200
NOTICE − Exceeding duty cycle
150 can damage unit and void
warranty.

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

6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes

duty1 4/95 − 150 215-A

3-3. Volt-Ampere Curves

1 1 Normal Volt-Ampere Curves
40
The volt-ampere curves show the
normal minimum and maximum
35 voltage and amperage output
capabilities of the welding power
30 source. Curves of other settings fall
between the curves shown.
25
Volts

20 Volt min
Volt max
15

10

0
0 50 100 150 200 250 300 350
Amperes
ssb1.1 10/91 − 239 342

TM-230 694 Page 4 Millermatic 252

 SECTION 4 − INSTALLATION
4-1. 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.

4-2. Selecting A Location

1 Line Disconnect Device
Locate unit near correct input
power supply.

Tipping ! Special installation may be

required where gasoline or
! Do not move or operate volatile liquids are present −
unit where it could tip. see NEC Article 511 or CEC
Section 20.

Location

18 in.
(460 mm)

18 in.
(460 mm)
loc_2 3/96 - Ref. 804 912-A

Millermatic 252 TM-230 694 Page 5

4-3. 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***
Weld Output
Terminals

! Turn off power be-

fore connecting to
weld output termi-
nals.
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
! Do not use worn, (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
damaged, under-
sized, or poorly
spliced cables.
10 − 60% 60 − 100%
Welding Duty Duty 10 − 100% Duty Cycle
Amperes Cycle 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)

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, 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

TM-230 694 Page 6 Millermatic 252

4-4. Connecting To Weld Output Terminals

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

4-5. 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.
Close door.

Tools Needed:
3/4 in.

804 909-A

Millermatic 252 TM-230 694 Page 7

4-6. Connecting Spoolmatic) 15A Or 30A Gun
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
6 Y-Adapter Fitting
Route shielding gas hose up to
regulator/flowmeter. Connect gas
hose to fitting on regulator/flowmeter.
2
. Two welding guns may be
3 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
triggers of both welding guns
1 are pulled at the same time, the
weld output and wirefeed motor
are disabled.

Tools Needed:
3/4, 5/8 in.
804 910-A

TM-230 694 Page 8 Millermatic 252

4-7. 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).
1 Gun End
2 Gun Liner
3 Wire Outlet Guide
Trim excess liner from end of gun
so no more than 3/32 in. (2.4 mm) of
liner extends past wire outlet guide.
4 Gun Securing Knob
3/32 in. Loosen securing knob. Insert gun
(2.4 mm) end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
Be sure to change drive rolls to the
4 proper size and type.
5 Gun Trigger Plug
Insert plug into receptacle, and
2 3 tighten threaded collar.

. If Aluma-Pro push/pull gun has

a listed SUP value, set the
power source to match the
SUP value (see Section 5-5).

. Be sure to trim liner to proper extension.

Ref. 804 910-A / 804 936-A

Millermatic 252 TM-230 694 Page 9

4-8. Setting Gun Polarity For Wire Type

Changing Polarity
1 Polarity Changeover Label
Information
Always read and follow manufacture’s
recommended 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. 190 821-A

4-9. Installing Gas Supply

1 Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
2 1 Cap
2 Cylinder Valve
Remove cap, stand to side of
3
4 valve, and open valve slightly. Gas
7 flow blows dust and dirt from valve.
Close valve.
Argon Gas Or Mixed Gas 3 Cylinder
4 Regulator/Flowmeter
1 Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
5 2
6 Welding Power Source Gas
Hose Connection
Connect customer supplied gas
3 hose between regulator/flowmeter
8 9 gas hose connection, and fitting on
rear of welding power source.
CO2 Gas 7 Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s recommended
flow rate.
8 CO2 Adapter (Customer
6 Supplied)
9 O-Ring (Customer Supplied)
Install adapter with O
ring between regulator/flowmeter
and CO2 cylinder.

Rear Panel

Tools Needed:
1-1/8, 5/8 in.
802 028-A / Ref. 804 912-A

TM-230 694 Page 10 Millermatic 252

4-10. 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.

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.

Order extra spring

Part No. 186 437

Remove these
components
from spindle.

Tools Needed:

15/16 in.
072573-B / 802 922

4-11. Positioning Jumper Links

Tools Needed: Check input voltage available at
site.
3/8 in. 1 Jumper Links Access Door
Open door.
2 Jumper Link Label
230VOLTS 460VOLTS 575VOLTS Check label − only one is on unit.
200VOLTS 230VOLTS
3 Input Voltage Jumper Links
Move jumper links to match input
3 voltage.
153980-D 144916-E
Close and secure access door.

153 980-D / 144 916-E / 804 911-A

Millermatic 252 TM-230 694 Page 11

 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) 200 230 400 460 575
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

Reference: 2011 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 amp), and UL class “H” ( 65 amp 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-230 694 Page 12 Millermatic 252

4-13. Connecting Input Power

5 =GND/PE Earth Ground

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.

Millermatic 252 TM-230 694 Page 13

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.

1 2 Tools Needed:
3
5 6

. Hold wire tightly to keep it

from unraveling.

6 in.
(150 mm)

Open pressure assembly. Pull and hold wire; cut off end.

. Use pressure indicator

Tighten 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. 802 064-D / S-0627-A

TM-230 694 Page 14 Millermatic 252

Notes

Millermatic 252 TM-230 694 Page 15

4-15. Weld Parameters

TM-230 694 Page 16 Millermatic 252

 226 650-B

Millermatic 252 TM-230 694 Page 17

 SECTION 5 − OPERATION
5-1. Controls
1 Voltage Control
Turn control clockwise to increase
voltage.
2 Wire Speed Control
Turn control clockwise to increase wire
feed speed.
3 Voltmeter
4 Wire Feed Speed Meter

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

TM-230 694 Page 18 Millermatic 252

 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
If the trigger on either gun is held for more and types. or Spool Gun Trigger while turning the
than 3 seconds without striking an arc, the Spool Gun Run−in is factory set at 50% power switch ON. The unit will power up
unit will automatically shut off weld power which is recommended for .030 & .035 with both the displays reading 888 , then
(and shielding gas output on MIG gun wire. A Run−in setting of 25% is the voltage display will read run and the
only), but will feed wire continuously at the recommended for .047 wire. wire feed display will read the preset
preset wire feed speed (which may be To check Run−in settings, start with the Run−in percentage from memory for the
faster or slower than Run−in Speed) until power switch OFF. Press and hold the MIG gun selected. To change the Run−in value,
trigger is released. or Spool Gun Trigger while turning the release the trigger and turn the wire feed
power switch ON. The unit will power up control knob (or the wire feed adjustment
Run−in Wire Feed Speed Settings with both the displays reading 888 , then knob located on the bottom handle of the
spool gun) to the desired setting for the
the voltage display will read run and the
selected gun. To return to weld mode after
Run−in settings for the MIG and Spool wire feed display will read the preset
the Run−in speed change, pull the trigger
Guns are independently set and stored in Run−in percentage from memory for the
momentarily (one second).
unit memory. The settings are in percent of gun selected. To return to the weld mode
the welding wire feed speed preset. Both without making a change, simply release
settings are adjustable from 25 to 150 trigger and pull the trigger again
percent. momentarily (one second).

Millermatic 252 TM-230 694 Page 19

5-2. Voltmeter And Wire Feed Speed Meter Operation

1 2

1 Voltmeter Welding Status Gun Selection

2 Wire Feed Speed Meter When either a MIG gun or spool gun trigger
The wire feed speed meter will display
is pressed and a welding arc is established,
preset wire feed speed (IPM) for the
Power Up Status the voltmeter displays actual weld voltage.
appropriate gun selection either MIG,
When the gun trigger is released and
Spool or Push/Pull gun. To preset desired
Both meters display 888 at unit power up. welding arc extinguished, the voltmeter
wire feed speed, connect desired gun,
After 0.5 seconds, preset values appear on displays the last actual voltage for 5
press gun trigger for one second, and
both meters. The settings for the last active seconds and then returns to preset voltage.
release trigger. The meter preset will be
gun used will be the default at initial power If welding resumes before unit displays
retained by the meter board until a different
up of the unit. If the power is reset to quickly, preset voltage, actual welding voltage will
gun is connected and preset is performed
characters other than 888 may appear. To appear on the voltmeter.
or the unit is turned off and back on. The
reset, turn power off for at least 3 seconds, The wire feed speed meter always displays settings for the last active gun used will be
then turn power back on. preset wire feed speed (IPM). the default at initial power up of the unit.

5-3. Jog Mode

If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut off
weld power (and shielding gas output on MIG or push/pull gun), but will feed wire continuously at the preset wire feed
speed (which may be faster or slower than Run−in Speed) until trigger is released. Jog wire feed speed is the same as
weld wire feed speed, so any time jog speed is changed, be sure to change back to weld wire feed speed before weld-
ing. Jog wire feed speed for the spool gun and push/pull gun is limited to 300 ipm (7.6 m/min).

TM-230 694 Page 20 Millermatic 252

5-4. Timers

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.

Millermatic 252 TM-230 694 Page 21

. Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.
5-5. Set Up Push Motor Torque (SUP) Or Reset (rES)

3 4

1 2

1 Voltage Control The following items can be adjusted by

rotating the left knob counterclockwise
. If Aluma-Pro push/pull gun has a listed
2 Wire Speed Control SUP value, set the power source to
(CCW):
match the SUP value.
3 Voltmeter Set up Push Motor Torque (SUP) − This
feature is only active when a push/pull gun To save settings and exit the (SUP) menu,
4 Wire Feed Speed Meter depress the gun trigger.
is connected to the welding power source.
Depress the gun trigger while turning on The (SUP) setting will adjust the Reset (rES) − Rotate the right knob to
the power switch until the left meter over-torque limit of the push motor inside select ON. Press and release gun trigger to
displays (run). the welding power source. The range is reset system to factory default values.
0-250 and the default value is 130.
Rotate the left knob counterclockwise Increasing this setting will increase the
(CCW) to find the particular item, and rotate over-torque limit and speed up the remote
the right knob to change the setting. wire feed speed motor.

TM-230 694 Page 22 Millermatic 252

Notes

Millermatic 252 TM-230 694 Page 23

 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
Z1 during arc start operation. RT1
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

13

Contactor W

14

Wire Drive Pulse Width

Motor PM Modulation

TM-230 694 Page 24 Millermatic 252

 10 Main Control Board PC1
Controls weld output by changing
the SCR gate pulses (conduction
times) after comparing voltage feed-
back 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-
7 8 9 ing motor speed feedback voltage
Stabilizer Z1 Positive (+) Wire signal to selected voltage signal.
And Start Output Drive 11 Thermistor RT1
Winding Terminal Assembly
If unit overheats, PC1 disables unit
Electrode stopping all weld output.
Contactor W
6 6 12 Gas Valve GS1
Burden Capacitor Controlled by circuitry on main
Resistor Bank C5 control board PC1.
R1
8 Work 13 Contactor W

Negative (−) Contactor W changes characteristic

Output of stabilizer Z1 during arc start op-
Terminal eration. Contactor is energized on
power up. Contactor drops out when
weld is established.
17
14 Wire Drive Motor PM
User Interface Feeds wire at speed set by PC2.
Board PC2
15 Gun Trigger Receptacle RC1
Connects gun trigger circuit to
welding power source.
16
16 Receptacle RC7
10-Pin Spool Connects optional Spoolmatic 30A
Gun And welding gun or push/pull gun.
Push/Pull
17 User Interface Board PC2
Receptacle
RC7 Sets process parameters for weld-
ing application.
15
Gun Trigger
Receptacle
RC1

AC Or DC Control Circuits

1φ Power

Weld Current Circuit

Millermatic 252 TM-230 694 Page 25

 SECTION 7 − TROUBLESHOOTING

7-1. 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 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 7-4 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).

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 7-6).

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).

Connect work clamp to get good metal-to-metal contact.

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

An overload condition occurred. Release gun trigger (see Section 8-2).

HL.P 003 appears on meters, check main control board and main rectifier.

Check SCR’s in 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 7-6).

TM-230 694 Page 26 Millermatic 252

 Trouble Remedy
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 7-6).

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 7-6).

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 7-6).

H002 message appears on displays to indicate thermistor RT detected unit is in an overheated condition
(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 7-6).

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 252 TM-230 694 Page 27

7-2. Help Displays

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

TM-230 694 Page 28 Millermatic 252

 . All directions are in reference to the S HLP 4 S HLP 8
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. 2 minutes without a welding arc established and held for 2 minutes without a welding arc
or there is a direct short between contact tip established.
S HLP 1 or wire and the workpiece. Release gun
trigger and clear fault condition. S HLP 9
Turn off primary input power and check input
voltage per primary voltage rating of welder, S HLP 5 Indicates XR-A gun trigger was pulled and
and correct if necessary. If HELP 1 persists, Indicates a malfunction in wire feed system held for 2 minutes without a welding arc
this Indicates a communication error and/or drive motor overcurrent condition. established.
between control board PC1 and user Check for proper spool brake adjustment or
interface board PC2. Contact a Service S HLP 10
obstructions in wire feed system. Clean or
Distributor or Factory Service Department. replace liner, wire guides, or contact tip. Indicates Python gun trigger was pulled and
S HLP 2 S HLP 6 held for 2 minutes without a welding arc
established.
Indicates overheating of unit. Unit will Indicates a malfunction in wire feed system
and/or external drive motor overcurrent con- S HLP 11
shutdown until internal temperature drops
within operational range. dition (spool gun or push-pull gun). Check for
proper spool brake adjustment or Indicates a communication error between
control board PC1 and user interface board
S HLP 3 obstructions in wire feed system. Clean or
PC2. Contact Factory Service Department.
replace liner, wire guides, or contact tip.
Indicates no open circuit voltage detected S HLP 12
S HLP 7
when gun trigger is pulled and no arc
detected after 3 seconds. Turn off primary Indicates spool gun trigger was pulled and Indicates Aluma-Pro gun trigger was pulled
input power and contact a Service held for 2 minutes without a welding arc and held for 2 minutes without a welding arc
Distributor or Factory Service Department. established. established.

SC-187 212-A

Millermatic 252 TM-230 694 Page 29

7-3. Troubleshooting Circuit Diagram For Welding Power Source
R4

R3

R3
R2

V2
R2

Waveform G
R1 Section 7-5

Waveform G
Section 7-5

V1

V1

V3

V4

V5

V6

See Section 7-6

For PC1 Data

TM-230 694 Page 30 Millermatic 252

 V2 and
Waveforms
A, B, C,
D, E, F
Section 7-5

V12

V8

V7

V11

V10

V9

Test Equipment Needed:

243035-C

Millermatic 252 TM-230 694 Page 31

7-4. Readings For Troubleshooting Circuit Diagram (All Models)
(Use With Section 7-3)
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

PC1 Key Inputs
V1 Power supply 24 volts AC
V2 OCV and Voltage Feedback +28 to 38 volts DC from min to max of voltage command signal
with gun trigger closed.
V3 Fan Motor Power 230 volts AC with fan off. 0 volts with fan running.
PC1 Key Outputs
V4* Gas Solenoid +35 volts DC with mig gun or push/pull gun trigger closed.
V5 Weld Stabilizer Control Contactor +35 volts DC when contactor is energized on power up. Contac-
(W Coil) tor coil deenergizes when weld is established.
V6* Drive motor +6 to 24 volts DC from min to max of wire feed speed command
with mig gun trigger closed.
V7 Power Supply +35 volts DC
V8 Power Supply +15 volts DC
V9 Mig Gun Trigger +35 volts DC with mig gun trigger open.
V10 Spool or Push/Pull Gun Trigger +35 volts DC with spool or push/pull gun trigger open.
V11 Spool or Push/Pull Gun Motor +3 to 20 volts DC from min to max of spool gun or push/pull
speed command with trigger closed.
PC2 Key Outputs
V12 Thermistor +1.5 to 4.0 volts DC depending on temperature.
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
*Voltage not present when triggered from Spool Gun connected to RC2.

TM-230 694 Page 32 Millermatic 252

Notes

Millermatic 252 TM-230 694 Page 33

7-5. Waveforms For Section 7-3
. 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

A. DC Open-Circuit Voltage, Voltage Control B. 14 Volts DC, 90 Amperes (Resistive Load)

At 14 Volts DC Preset

5 ms 10 V 5 ms 5 V

gnd

gnd

D. 20 Volts DC, 130 Amperes (Resistive Load)

C. DC Open-Circuit Voltage, Voltage Control At
20 Volts DC Preset

TM-230 694 Page 34 Millermatic 252

 5 ms 10 V 5 ms 5 V

gnd

gnd

F. 29.4 Volts DC, Voltage Control At

Maximum (Resistive Load)
E. DC Open-Circuit Voltage, Voltage Control
At Maximum 29.5 Volts DC Preset

2 ms 2V

gnd

G. SCR Gate Pulses With Respect To Cathode

At No Load

Test Equipment Needed:

Millermatic 252 TM-230 694 Page 35

7-6. Main Control Board PC1 Testing Information (Use With Section 7-7)
Be sure plugs are secure before
testing. See Section 7-7 for specific
values during testing.
1 Main Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC4
2 1 6 Receptacle RC5
7 Receptacle RC7
8 Receptacle RC8

Factory
6 use only
5
7 8

Test Equipment Needed:

238 934-A / 804 921-A

TM-230 694 Page 36 Millermatic 252

7-7. 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 7-5)

2 Gate pulse to SCR module with respect to pin RC1-3 (see Section 7-5)

3 SCR gate pulse return

4 SCR gate pulse return

RC2 1 Voltage feedback +28 to +38 volts DC with respect to pin RC2-2

2 Voltage feedback return

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

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

5 Drive motor +6 to +24 volts DC (±3 volts DC) with respect to RC2-9

6 Current detect with respect to pin RC2-1

7 Contactor return

8 Gas valve return

9 Drive motor return

10 No testing required

11 No testing required

12 No testing required

13 No testing required

14 No testing required

RC3 1 MIG gun trigger in +35 volts DC

2 MIG gun trigger in return

3 Spool gun or push/pull gun trigger in +35 volts DC

4 Spool gun or push/pull gun trigger return

5 Spool gun or push/pull gun motor +3 to +20 volts DC

6 Spool gun or push/pull gun motor return

Millermatic 252 TM-230 694 Page 37

 Receptacle Pin Values

RC4 1 Receive to PC2

2 Transmit to PC2

3 +35 volts DC output to PC2

4 Ground to PC2

5 Ground to PC2

6 +15 volts DC output to PC2

RC5 All No testing required

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

TM-230 694 Page 38 Millermatic 252

7-8. User Interface Board PC2 Testing Information (Use With Section 7-9)
Be sure plugs are secure before test-
ing. See Section 7-7 for specific val-
ues during testing.
1 User Interface Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC5

Test Equipment Needed:

238 939-A / 803 046

Millermatic 252 TM-230 694 Page 39

7-9. User Interface Board PC2 Test Point Values

a) Tolerance − ±10% unless specified

PC2 Voltage Readings b) Reference − to circuit common
(lead 1) unless noted
c) Triggered − means gun trigger is
pressed

Receptacle Pin Values

RC1 1 Transmit from PC1

2 Receive from PC1

3 +35 volts DC from PC1

4 Ground from PC1

5 Ground from PC1

RC2 All No testing required

RC3 1 Spool gun or push/pull gun potentiometer ground

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

4 Gun detect +5 volts DC for push/pull gun

RC5 1 Thermistor input

2 +15 volts DC from PC1

3 Thermistor ground with respect to pin RC5-1

TM-230 694 Page 40 Millermatic 252

7-10. Pre-Operational Check

1 Weld Output Terminals

Check open-circuit voltage between
terminals according to Section 7-4
(voltage V2).

. Also use output waveforms to

check unit output after servicing
(see Section 7-5).
If correct voltages are not present,
Pre-Operational Checklist repeat troubleshooting procedures in
n Section 7-1.
Clean and blow out inside of unit. n ! Disconnect input power and
Clean weld output terminals. Tighten connections. n let unit cool.

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.

Test Equipment Needed:

Tools Needed:

3/4 in.

3/8 in.

804 921-A / Ref. 804 909-A

Millermatic 252 TM-230 694 Page 41

 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 ~ Clean Drive Rolls

Or Grease To Drive Motor
Shaft

8-2. Unit Overload

Thermistor RT1 in SCR1 protects the unit from damage due to overheating. If HL.P 002 is displayed on the meters,
wait for unit to cool allowing fan motor to run before trying to weld.

8-3. Changing Drive Roll and Wire Inlet Guide

1 Securing Screw
2 2 Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
4
3 Drive Roll
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
1 drive roll. The groove closest to the
motor shaft is the proper groove to
thread (see Section 4-14).
4 Drive Roll Securing Nut
Turn nut one click to secure drive
roll.

Tools Needed:

7/16 in
Ref. 804 914-A

TM-230 694 Page 42 Millermatic 252

8-4. Aligning Drive Rolls and Wire Guide
! Turn Off power.
View is from top of drive rolls
looking 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. 800 412-A

Millermatic 252 TM-230 694 Page 43

Notes

TM-230 694 Page 44 Millermatic 252

 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 252 LG290851B thru LK180128N and 229 485-B ♦♦

LK200006N thru LK510154N

LK180129N thru LK200005N and 243 035-C ♦♦

LK510151N and following

Circuit Board PC1 LG290851B thru LK180128N and 226 413-E ♦♦ ♦♦

LK200006N thru LK510150N

LK180129N thru LK200005N and 238 935-A ♦♦ ♦♦

LK510151N and following

Circuit Board PC2 LG290851B thru LK510150N 226 405-C ♦♦ ♦♦

LK510151N and following 238 940-A ♦♦ ♦♦

♦♦ Not included in this manual

Millermatic 252 TM-230 694 Page 45

 Figure 9-1. Circuit Diagram For Millermatic 252 Eff w/LG290851B Thru LK180128N And
Eff w/LK200006N Thru LK510154N

TM-230 694 Page 46 Millermatic 252

 229 485-B

Millermatic 252 TM-230 694 Page 47

Figure 9-2. Circuit Diagram For Millermatic 252 LK180129N Thru LK200005N And LK510151N And Following

TM-230 694 Page 48 Millermatic 252

 243 035-C

Millermatic 252 TM-230 694 Page 49

 Table 9-1. Lead List Summary For Millermatic 252 [200 (208)/230 Volts] Models Eff w/LG290851B Thru
LK180128N And Eff w/LK200006N Thru LK510150N
. 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. 603 978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−A NEGATIVE OUTPUT STUD TO WORK CLAMP 0034A PLG3 (3) TO RC2 (D)
−−−− DRIVE CASTING TO POSITIVE OUTPUT 0035A RC2 (E) TO PLG13 (3)
0002A POWER SWITCH INSIDE LEAD TO TE1 (2) 0036A RC2 (F) TO PLG13 (2)
0003A FAN MOTOR TO TE1 0040A RC1 (1) TO PLG3 (1)
0003A POWER SWITCH OUTSIDE LEAD TO TE1 (5) 0042A PLG8 (2) TO PLG2 (2)
0008A PLG6 (3) TO PLG12 (3) 0042B PLG8 (3) TO PLG2 (3)
0009A PLG5 (4) TO GS1 0043A C5 (NEG) TO RECTIFIER HEAT SINK
0010A PLG5 (8) TO GS1 0043B RECTIFIER HEAT SINK TO NEG OUTPUT
0011A PLG8 (1) TO PLG2 (1) 0043C C5 (−) TO R1
0012A PLG8 (4) TO PLG2 (4) 0043D PLG5 (2) TO C5 (−)
0013A PLG5 (3) TO W (COIL) 0044B SECONDARY C.T. XFMR TO C5 (POS)
0014 PLG6 (5) TO PLG12 (5) 0044C W (TOP) TO C5 (+)
0015 PLG6 (6) TO PLG14 (2) 0044D W (TOP) TO R1
0016A PLG3 (5) TO RC2 (C) 0044E PLG5 (6) TO W (TOP)
0017 PLG14 (1) TO PLG11 (1) 0046A PLG5 (1) TO POS STUD
0018 PLG14 (3) TO PLG11 (2) 0047A RC2 (G) TO PLG3 (4)
0019A RC1 (2) TO PLG3 (2) 0052A PLG3 (6) TO RC2 (B)
0020A FAN MOTOR TO PLG7 (2) 0059A PLG5 (9) TO MOTOR PLUG (2)
0021A TE1 TO PLG7 (1) 0060 PLG6 (2) TO PLG12 (2)
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)

TM-230 694 Page 50 Millermatic 252

 Figure 9-2. Lead List Summary For Millermatic 252 (230/460/575 Volts) Models Eff w/LG290851B Thru
LK180128N And Eff w/LK200006N Thru LK510150N
. 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. 603 978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−A NEGATIVE OUTPUT STUD TO WORK CLAMP 0035A RC2 (E) TO PLG13 (3)
−−−− DRIVE CASTING TO (+) OUTPUT STUD 0036A RC2 (F) TO PLG13 (2)
0002A POWER SWITCH INSIDE LEAD TO TE1 (2) 0040A RC1 (1) TO PLG3 (1)
0003A FAN MOTOR TO TE1 0042A PLG8 (2) TO PLG2 (2)
0008 PLG6 (3) TO PLG12 (3) 0042B PLG8 (3) TO PLG2 (3)
0009A PLG5 (4) TO GS1 0043A C5 (NEG) TO RECTIFIER HEAT SINK
0010A PLG5 (8) TO GS1 0043B RECTIFIER HEAT SINK TO NEG OUTPUT
0011A PLG8 (1) TO PLG2 (1) 0043C C5 (−) TO R1
0012A PLG8 (4) TO PLG2 (4) 0043D PLG5 (2) TO C5 (−)
0013A PLG5 (3) TO W (COIL) 0044B SECONDARY C.T. XFMR TO C5 (POS)
0014 PLG6 (5) TO PLG12 (5) 0044C W (TOP) TO C5 (+)
0015 PLG6 (6) TO PLG14 (2) 0044D W (TOP) TO R1
0016A PLG3 (5) TO RC2 (C) 0044E PLG5 (6) TO W (TOP)
0017 PLG14 (1) TO PLG11 (1) 0046A PLG5 (1) TO POS STUD
0018 PLG14 (3) TO PLG11 (2) 0047A RC2 (G) TO PLG3 (4)
0019A RC1 (2) TO PLG3 (2) 0052A PLG3 (6) TO RC2 (B)
0020A FAN MOTOR TO PLG7 (2) 0059A PLG5 (9) TO MOTOR PLUG (2)
0021A TE1 TO PLG7 (1) 0060 PLG6 (2) TO PLG12 (2)
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

Millermatic 252 TM-230 694 Page 51

 Figure 9-3. Lead List Summary For Millermatic 252 [200 (208)/230 Volts] Models Eff w/LK180129N Thru
LK200005N And Eff w/LK510151N 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. 603 978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−A NEGATIVE OUTPUT STUD TO WORK CLAMP 0034A PLG3 (3) TO RC2 (D)
−−−− DRIVE CASTING TO POSITIVE OUTPUT 0035A RC2 (E) TO PLG13 (3)
0002A POWER SWITCH INSIDE LEAD TO TE1 (2) 0036A RC2 (F) TO PLG13 (2)
0003A FAN MOTOR TO TE1 0040A RC1 (1) TO PLG3 (1)
0003A POWER SWITCH OUTSIDE LEAD TO TE1 (5) 0043A C5 (NEG) TO RECTIFIER HEAT SINK
0008A PLG6 (3) TO PLG12 (3) 0043B RECTIFIER HEAT SINK TO NEG OUTPUT
0009A PLG5 (4) TO GS1 0043C C5 (−) TO R1
0010A PLG5 (8) TO GS1 0043D PLG5 (2) TO C5 (−)
0013A PLG5 (3) TO W (COIL) 0044B SECONDARY C.T. XFMR TO C5 (POS)
0014 PLG6 (5) TO PLG12 (5) 0044C W (TOP) TO C5 (+)
0015 PLG6 (6) TO PLG14 (2) 0044D W (TOP) TO R1
0016A PLG3 (5) TO RC2 (C) 0044E PLG5 (6) TO W (TOP)
0017 PLG14 (1) TO PLG11 (1) 0046A PLG5 (1) TO POS STUD
0018 PLG14 (3) TO PLG11 (2) 0047A RC2 (G) TO PLG3 (4)
0019A RC1 (2) TO PLG3 (2) 0052A PLG3 (6) TO RC2 (B)
0020A FAN MOTOR TO PLG7 (2) 0059A PLG5 (9) TO MOTOR PLUG (2)
0021A TE1 TO PLG7 (1) 0060 PLG6 (2) TO PLG12 (2)
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)

TM-230 694 Page 52 Millermatic 252

 Figure 9-4. Lead List Summary For Millermatic 252 (230/460/575 Volts) Models Eff w/LK180129N Thru
LK200005N And Eff w/LK510151N 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. 603 978) to terminals where factory-applied compound had been
present.
Apply small amount of dielectric grade, nonconductive electric grease (Part No. 146 557) to connectors where factory-applied
grease had been present.

Lead Connections Lead Connections

−−−−A NEGATIVE OUTPUT STUD TO WORK CLAMP 0035A RC2 (E) TO PLG13 (3)
−−−− DRIVE CASTING TO (+) OUTPUT STUD 0036A RC2 (F) TO PLG13 (2)
0002A POWER SWITCH INSIDE LEAD TO TE1 (2) 0040A RC1 (1) TO PLG3 (1)
0003A FAN MOTOR TO TE1 0043B RECTIFIER HEAT SINK TO NEG OUTPUT
0008 PLG6 (3) TO PLG12 (3) 0043C C5 (−) TO R1
0009A PLG5 (4) TO GS1
0043D PLG5 (2) TO C5 (−)
0010A PLG5 (8) TO GS1
0044B SECONDARY C.T. XFMR TO C5 (POS)
0013A PLG5 (3) TO W (COIL)
0044C W (TOP) TO C5 (+)
0014 PLG6 (5) TO PLG12 (5)
0044D W (TOP) TO R1
0015 PLG6 (6) TO PLG14 (2)
0044E PLG5 (6) TO W (TOP)
0016A PLG3 (5) TO RC2 (C)
0046A PLG5 (1) TO POS STUD
0017 PLG14 (1) TO PLG11 (1)
0047A RC2 (G) TO PLG3 (4)
0018 PLG14 (3) TO PLG11 (2)
0052A PLG3 (6) TO RC2 (B)
0019A RC1 (2) TO PLG3 (2)
0020A FAN MOTOR TO PLG7 (2) 0059A PLG5 (9) TO MOTOR PLUG (2)

0021A TE1 TO PLG7 (1) 0060 PLG6 (2) TO PLG12 (2)

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

Millermatic 252 TM-230 694 Page 53

Notes

TM-230 694 Page 54 Millermatic 252

 TM-230694U 2018−09
Eff. w/Serial Number LG290851B And
Following

Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source

and Wire Feeder

Millermatic 252
R

For product information, File: MIG (GMAW)

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 SECTION 10 − PARTS LIST

. Hardware is common and

9 not available unless listed.

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

Figure 10-1. Main Assembly

TM-230 694 Page 56 Millermatic 252
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-1. Main Assembly

. . . 1 . . . . . . . Figure 10-2 . . Baffle, Center w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . Z1 . . 231536 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . Figure 10-4 . . Panel, Rear w/Components, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 229621 . . Panel, Side LH Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 230363 . . Latch, Slide Flush Mtg Hole 1.750 Widex 1.500 Lg . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 229620 . . Door, Hinged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . +229619 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 231983 . . Label, Warning General Precautionary (En/Sp) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 231984 . . Label, Warning Electric Shock/Incorr Input (En/Sp) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 269479 . . Cord Set, 250V 6−50P 8−10ga 3/C 12ft st JKT (200/230) . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . +269477 . . Cord Set, 250V T tng 8−10ga 3/C 12ft st JKT (230/460/575) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 231988 . . Label, Warning Electric Shock Power Cord (En/Sp) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 232262 . . Rectifier Assy, SCR Main (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 205946 . . . . Foot, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 232260 . . . . Rectifier, SCR Main (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG5 . . 115094 . . . . . Housing Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . SR1 . . 197698 . . . . . Thyristor, SCR Module 300a 400v Common Anode . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 232261 . . . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . C3,4 . 219460 . . . . . Capacitor, Cer Disc .01 uf 1000 VDC w/Terms . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . RT1 . . 173632 . . . . . Thermistor, NTC 30k ohm @ 25 Deg C 12in Lead . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 230798 . . Axle, Running Gear .750 Dia x 18.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 230799 . . Wheel, Polypropylene 10 in x 2.25 Wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . 602250 . . Washer, Flat .812ID x1.469OD x.134t Stl Pld ANSI .750 . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . 121614 . . Ring, Rtng Ext .750 Shaft x .085 Thk E Style Pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . 229625 . . Tray, Cylinder Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 169598 . . M−25 Gun 15 ft .030−.035 Wire (See Gun Owner’s Manual) . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . Figure 10-3 . . Panel, Front w/Components, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 209870 . . Caster, Swvl 4.00 in Polyolefin x 1.250 in Wide
(Prior To LH420406B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . 235875 . . Caster, Swvl 4.00 in Polyolefin x 1.250 in Wide
(Eff w/LH420406B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . 229624 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 230364 . . Baffle, Air Xfmr (Prior To MA220158N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 248427 . . Baffle, Air Xfmr (Eff w/MA220158N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 248426 . . Blank, Snap−in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . T1 . . 246555 . . Kit, Xfmr Mm252 200/230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . T1 . . 246556 . . Kit, Xfmr Mm252 230/460/575V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . . 110760 . . Housing Receptacle & Skts
(Eff w/LG290851B Thru LK180128N and LK200006N thru LK510150N) . . . . 1
. . . . . . . . PLG4 . 096530 . . Conn, Rect Comm 093 4P/S 1row RC
PT Cable Molex LKG
(Eff w/LG290851B thru LK180128N and LK200006N thru LK510150N) . . . . . 1
. . . . . . . . PLG8 . 096530 . . Conn, Rect Comm 093 4P/S 1row RC
PT Cable Molex LKG
(Eff w/LK180129N thru LK200005N and Eff w/LK510151N and following) . . . 1
................ 234263 . . Regulator/Flowmeter, 0−50 CFH AR/CO2/Mix w/Filter . . . . . . . . . . . . . . . . . . . 1
................ 196328 . . Cable, Work 10 ft No 3 w/Clamp & Boot (Including) . . . . . . . . . . . . . . . . . . . . . . 1
................ 233452 . . . . Clamp, Work 300 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 600318 . . . . Cable, Weld Cop Strd No 3 EPDM JKT (order by ft) . . . . . . . . . . . . . . . . . . . . 1
................ 196318 . . . . Cover, Cable BTRY Post BLK .75 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 144108 . . Hose, Gas 5 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+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

Figure 10-2. Baffle, Center w/Components

TM-230 694 Page 58 Millermatic 252

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Baffle, Center w/Components

................ 196001 . . Spool Hub Assembly (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .......... 058427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .......... 057745 . . . . Spring, CPRSN 2.305 OD x .090 Wire x 2.500 Pld . . . . . . . . . . . . . . . . . . . . . 1
... 3 .......... 186435 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .......... 085980 . . Nut, 625−11 .94 Hex .54h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .......... 605941 . . Washer, Flat .640 ID x1.000 OD x.075T Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .......... 186437 . . Spring, CPRSN .845 OD x .110 Wire x 1.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 057971 . . Washer, Flat .632 ID x1.500 OD x.125T Stl Pld .175 Key . . . . . . . . . . . . . . . . . 1
... 8 .......... 186436 . . Washer, Brake Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .......... 229623 . . Baffle, Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 231985 . . Label, Warning Electric Shock And Pinch (En/Sp) . . . . . . . . . . . . . . . . . . . . . . . 1
................ 226658 . . Label, Polarity/Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 153980 . . Label, Link Arr Pri V 200/230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 144916 . . Label, Link Arr Pri V 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 185644 . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . C5 . . 184584 . . . . Capacitor, ELCTLT 15000 uf 45 VDC Can 1.395 . . . . . . . . . . . . . . . . . . . . . . . 8
................ 083147 . . . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . . . 6
. . . 12 . . . . . . . . . . 229801 . . . . Kit, Capacitor Buss Bar & Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 177307 . . Reel Support (Prior To LH420484B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 235827 . . Reel Support (Eff w/LH420484B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . W . . . 229685 . . Contactor, DEF PRP 25A 1P 36VDC Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . PC1 . . 243257 . . Kit, Field Millermatic 252 CNTL BD
Replacement (Prior To MB030069N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . PC1 . . 249885 . . Circuit Card Assy, Control (Eff w/MB030070N thru MB030479N) . . . . . . . . . . 1
. . . 15 . . . PC1 . . 243257 . . Kit, Field Millermatic 252 CNTL BD
Replacement (Eff w/MB030480N thru MB200506N) . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . PC1 . . 249885 . . Circuit Card Assy, Control (Eff w/MB200507N and following) . . . . . . . . . . . . . . 1
. . . . . . . . PLG1 . . 115094 . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG5 . 130203 . . Housing Rcpt+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3 . . 115092 . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . 115093 . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG7 . 202592 . . Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG8 . 201665 . . Housing Plug+Skts (Service Kit) (Prior to LK180129N) . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . R1 . . . 119998 . . Resistor, WW Fxd 300 W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 129524 . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . POS . 097421 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . C1,C2 . 128750 . . Capacitor, Cer Disc .1 uf 500 VDC w/Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . NEG . 097416 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230687 . . Drive Assy, Wire w/Pri Link 3V (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230362 . . Drive Assy, Wire w/Pri Link 2V (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . Figure 10-5 . . . . Motor And Wire Drive Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 229630 . . . . Housing, Drive Assy/Pri Term Link 2 Voltage (Including) . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 229631 . . . . Housing, Drive Assy/Pri Term Link 3 Voltage (Including) . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 231987 . . . . . Label, Warning High Voltage (En/Sp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 229634 . . . . . Door, Access Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . 134201 . . Stand−off Support, PC Card .312/.375 w/Post&lock .43 . . . . . . . . . . . . . . . . . . 3
. . . 26 . . . . . . . . . . 228 165 . . Grommet, SCR No 8 Panel Hole .312 x .343 .515 High . . . . . . . . . . . . . . . . . . 1

+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 59

 . Hardware is common and
not available unless listed. 5 6
4

3
7
2

8
9

15
14
10

11

13
17
12
16
804 917-A

Figure 10-3. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 10-3. Panel, Front w/Components

. . . 1 . . . . . . . . . . 230304 .. Bezel, Front w/Consumable Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . 226660 .. Label, Power/Mig Gun/Spoolgun MM252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 226647 .. Label, Controls Millermatic 252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 228165 .. Grommet, SCR No 8 Panel Hole .312 x .343 .515 High . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 134201 .. Stand−off Support, PC Card .312/.375 w/Post&lock .43 . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . 225276 .. Panel, Front 252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 238079 .. Enclosure, PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . PC2 . . 238937 .. Circuit Card Assy, User IFC w/Program MM252 (R) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG12 131055 .. Housing Rcpt+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG13 201665 .. Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG14 131204 .. Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . RC2 . . 189238 .. Conn, CIRC MS/CPC 10 Skt Size 18 Rcpt Panel Pushin . . . . . . . . . . . . . . . . . 1
. . . 9 . . . RC1 . . 048282 .. Rcpt w/Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . S1 . . 246667 .. Switch, TGL DPST 40A 600VAC SCR Term Wide TGL . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . S1 . . . 124511 .. Switch, TGL DPST 40A 600VAC SCR Term (Eff w/MA350615N) . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 226650 .. Flip Chart, Millermatic 252 Para/Hlp/Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230365 .. Clip, Snap In .250 ID X .250 Mt Hole x .030−.125 Pnl . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . 226659 .. Label, Nameplate Millermatic 252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 229617 .. Tray, Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 229618 .. Cover, Tray Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 226653 .. Label, Consumables M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 218764 .. Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . 231553 .. Handle, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 231554 .. Handle, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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.
TM-230 694 Page 60 Millermatic 252
. Hardware is common and
not available unless listed. 11
10

12

8
7
6

13

4 5 14

804 918-A

Figure 10-4. Panel, Rear w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 10-4. Panel, Rear w/Components

... 1 . . . . . . . . . . 049399 .. Nut, 312−18 Push On .63d .07h Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . 148809 .. Blade, Fan 9.000 5wg 34deg .312 Bore CCW Plstc . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . FM . . 188706 .. Motor, Fan 230V 50/60Hz 1550 RPM .312 Dia Shaft . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . 225669 .. Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . 010493 .. Bushing, Snap−in Nyl .625 ID x .875 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . 146524 .. Hose, SAE .187 ID x .410 OD X 27.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . 149332 .. Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . . GS1 . . 216395 .. Valve, 34VDC 2 Way Custom Port 1/8 ORF w/Frict . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . 225282 .. Panel, Rear 252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . +229628 .. Bracket, Support Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 231986 .. Label, Warning Cyl May Explode If Damaged (En/Sp) . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . 188441 .. Chain, Weldless 2/0 x 31. Bright Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . 137761 .. Nut, 750 NPT 1.31hex .27h Nyl Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . 604102 .. Conn, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+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

Figure 10-5. Wire Drive And Gears

... 1 .......... 174609 . . Screw, M 4− .7 x 12 Cheese Hd Blk Din 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .......... 173619 . . Carrier, Drive Roll w/Components 24 Pitch 10mm Shaf . . . . . . . . . . . . . . . . . . 1
... 3 .......... 174610 . . Screw, M 6−1.0 x 20 Soc Hd Button Cap Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .......... 192029 . . Washer, Flat .250 ID x0.437 OD x.015t Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 5 .......... 173620 . . Bushing, Mtg Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 .......... 221912 . . Guide, Wire Inlet Nylon .023 − .052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 010224 . . Pin, Spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 221976 . . Knob, Tension Adjust Assy (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 225718 . . . . Fastener, Pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .......... 196896 . . . . Cup, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 196897 . . . . Spring, CPRSN .695 OD x .095 Wire x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 196895 . . . . Knob, Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . M . . . 225341 . . Motor, Gear 24VDC 150 RPM 24:1 Ratio (Prior to MB030069N) . . . . . . . . . . . 1
. . . 12 . . . . M . . . 249883 . . Motor, Gear 24VDC 150 RPM 24:1 Ratio
(Eff w/MB030070N thru MB030479N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . M . . . 225341 . . Motor, Gear 24VDC 150 RPM 24:1 Ratio
(Eff w/MB030480N thru MB200506N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . M . . . 249883 . . Motor, Gear 24VDC 150 RPM 37:5 Ratio
(Eff w/MB200507N and following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 228828 . . Lever, Mtg Pressure Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 230801 . . Spring, Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 166072 . . Spacer, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 172075 . . Carrier, Drive Roll w/Components 24 Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 079633 . . Ftg, Hose Brs Barbed Nipple 3/16 TBG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 602009 . . Screw, 250−20 x 1.25 Soc Hd−hex Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 151828 . . Pin, Cotter Hair .042 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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.

TM-230 694 Page 62 Millermatic 252

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-5. Wire Drive And Gears (Continued)

. . . 19 . . . . . . . . . . 234784 . . Pin, Clevis .250 OD x 1.751 Lg w/Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . 230801 . . Spring, Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 228826 . . Housing, Adapter Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 204585 . . Knob, Fluted 1.75 in w/ .312−18 Stud 1.00 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 604538 . . Washer, Flat .344 ID x0.688 OD x.065t Stl Pld ANSI .312 . . . . . . . . . . . . . . . . 3
. . . 24 . . . . . . . . . . . 602211 . . Washer, Lock .318 ID x 0.586 OD x .078t Stl Pld Split .312 . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . 604534 . . Screw, 312−18 x 1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 203526 . . Roll, Drive V Groove .030−.035 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
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.
10-1. Drive Roll And Wire Guide Kits
. Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).

Wire Diameter Drive Roll Inlet

Kit No. Wire Guide
Fraction Decimal Metric Part No. Type
.023/.025 in. .023/.025 in. 0.6 mm 087 131 087 130 V-Grooved 056 192
.030/.035 in. .030/.035 in. 0.8/0.9 mm 204 579 203 526 V-Grooved 056 192

.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

Millermatic 252 TM-230 694 Page 63

Notes

TM-230 694 Page 64 Millermatic 252

Notes

Millermatic 252 TM-230 694 Page 65

 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 © 2018 Miller Electric Mfg. LLC 2018−01