Manual for MILLERMATIC 252 - Troubleshooting and error codes + PDF Download

Manual for MILLERMATIC 252 - Troubleshooting and error codes + PDF Download

Brand: MILLER

Category: Welding System

Manual Type:

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Uploaded: April 8, 2025, 1:39 p.m.

Manual Publish Date: 2011-08

Warranty Summary

Miller Electric Mfg. Co. warrants to the original retail purchaser that new Miller equipment is free of defects in material and workmanship for a period of up to 5 years parts and 3 years labor depending on the component.
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Operation Summary

The Miller Millermatic 252 is a MIG (GMAW) and Flux Cored (FCAW) welding power source and wire feeder.

Basic Operation Steps:

  1. Installation: Connect input power, weld cables, work clamp, shielding gas supply, and wire spool.
  2. Setup: Select wire type and diameter, adjust hub tension, and position jumper links for input voltage.
  3. Controls: Use voltage and wire speed controls to set welding parameters.
  4. Welding: Thread welding wire, set weld parameters, hold and position welding gun, and perform weld.
  5. Maintenance: Perform routine maintenance as per the manual's schedule and troubleshooting guidelines if issues arise.

Troubleshooting and error codes

Problem Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 5-13). Replace building line fuse or reset circuit breaker if open (see Section 5-13). Secure gun trigger connections (see welding gun Owner's Manual). HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again, have Factory Authorized Service Agent check unit. 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, have Factory Authorized Service Agent check for an open Thermistor RT1 (see Section 7-2). HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing short circuit (see Section 6-2). If message remains, have Factory Authorized Service Agent check for shorted trigger leads. Have Factory Authorized Service Agent check Power switch. Have Factory Authorized Service Agent check all board connections and main control board.
No Weld Output; wire feeds. Connect work clamp to get good metal to metal contact. Replace contact tip (see welding gun Owner's Manual. HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and main rectifier.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 5-13). Check input voltage jumper links and correct position if necessary (see Section 5-11). Have Factory Authorized Service Agent check main control board.
Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.
Low, high, or erratic wire speed. Readjust front panel settings (see Section 6-1). Change to correct size drive rolls (see Section 7-3). Readjust drive roll pressure (see Section 5-14). Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner's Manual). Check position of input jumper links (see Section 5-11). Have Factory Authorized Service Agent check main control board.

Troubleshooting and error codes

Problem Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 5-13). Replace building line fuse or reset circuit breaker if open (see Section 5-13). Secure gun trigger connections (see welding gun Owner's Manual). HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again, have Factory Authorized Service Agent check unit. 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, have Factory Authorized Service Agent check for an open Thermistor RT1 (see Section 7-2). HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing short circuit (see Section 6-2). If message remains, have Factory Authorized Service Agent check for shorted trigger leads. Have Factory Authorized Service Agent check Power switch. Have Factory Authorized Service Agent check all board connections and main control board.
No Weld Output; wire feeds. Connect work clamp to get good metal to metal contact. Replace contact tip (see welding gun Owner's Manual. HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and main rectifier.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 5-13). Check input voltage jumper links and correct position if necessary (see Section 5-11). Have Factory Authorized Service Agent check main control board.
Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.
Low, high, or erratic wire speed. Readjust front panel settings (see Section 6-1). Change to correct size drive rolls (see Section 7-3). Readjust drive roll pressure (see Section 5-14). Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner's Manual). Check position of input jumper links (see Section 5-11). Have Factory Authorized Service Agent check main control board.