Issued March 2016 • Index No. DC/12.

49

Millermatic 252 ® MIG Power Source,

Wire Feeder and Gun Package

Industrial Processes Amperage Range 30–300 A

Applications MIG (GMAW) Rated Output 200 A at 28 VDC, 60% duty cycle
Quick Metal fabrication
Maintenance and repair
Flux-cored (FCAW) 250 A at 28 VDC, 40% duty cycle

Specs Farm/home Input Power Wire Feed Speed 50–700 ipm (1.3–17.8 m/min.)
Light industrial 200(208)/230 V, 1-phase, 60 Hz Max. Open-Circuit Voltage 38 V
230/460/575 V, 1-phase, 60 Hz
Net Weight 207 lb. (94 kg)

Highest output in its class

(250 A at 28 VDC). Weld longer Comes complete with:
on high-end applications. 15 ft. (4.6 m), 250-amp M-25 MIG gun
10 ft. (3 m) work cable with clamp
Infinite voltage control with 10 ft. (3 m) industrial power cord
self-calibrating digital meters (with plug on 200/230 V model)
that permit presetting of voltage Flow gauge regulator and gas hose for argon
and wire feed speed. Ensures or AR/CO2 mix
precise parameters and accuracy. Factory-installed lowered running gear/
cylinder rack
Integrated digital timers come .030/.035 in. reversible dual-groove drive rolls
complete with presettable preflow/ Extra contact tips
postflow, burnback, spot and delay
(stitch) timers. Independent timers
for MIG and spool gun.

Line voltage compensation

keeps power constant even
if power input varies by
±10 percent.
EZ-Access™ consumable
Active Arc Stabilizer ™ compartment and parameter
minimizes weld cleanup, and chart. Set weld parameters right
provides excellent starts proven the first time with convenient
superior to the competition. flip-down compartment that
provides fast access to parameter
Auto Gun Detect™ allows chart and consumables. See
operator to simply pull trigger page 3 for more information.
on MIG gun, spool gun or
push/pull gun. Automatically detects
and recalls the voltage, wire feed
speed and timer of the active gun.
See page 3 for more information.

Heavy-duty aluminum, two-drive-roll system. Superior aluminum MIG welding with

direct connection of optional push-pull
™
Fan-On-Demand power source cooling system guns and spool guns. Now directly
operates only when needed, reducing noise, connect your XR™ push-pull guns or
energy use and the amount of contaminants Spoolmate™ 200 and Spoolmatic® spool
pulled though the machine. guns. No extra module to buy or install.

Welder is warranted for three years, parts and labor.

Original main power rectified parts are warranted for five years.
Gun warranted for 90 days, parts and labor.

Miller Electric Mfg. Co. Equipment Sales US and Canada [Link]

An ITW Welding Company Phone: 866-931-9730
1635 West Spencer Street FAX: 800-637-2315
P.O. Box 1079 International Phone: 920-735-4554
Appleton, WI 54912-1079 USA International FAX: 920-735-4125
 Specifications (Subject to change without notice.)
Max.
Max. Open-
Amperage Amps Input at Rated Output, 60 Hz Wire Feed Wire Type and Spool Circuit Net
Range Rated Output 200(208) V 230 V 460 V 575 V KVA KW Speed Diameter Size Voltage Dimensions Weight
30–300 A 200 A at 28 VDC, 48 42 21 17 9.8 7.5 50–700 ipm Solid/stainless steel: 12 in. 38 H: 30 in. 207 lb.
60% duty cycle 2.3* 2* 1* 0.8* 0.46* 0.13* (1.3 –17.8 .023 –.045 in. (305 mm) (762 mm) (94 kg)
250 A at 28 VDC, m/min.) (0.6 –1.2 mm) W: 19 in.
40% duty cycle Flux-cored: (483 mm)
.030 –.045 in. D: 40 in.
(0.8 –1.2 mm) (1,016 mm)

*While idling.
Note: Operating temperature range: -4° to +104°F (-20° to +40°C). Storage temperature range: -22° to +122°F (-30° to +50°C).

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Control Panel

1 3
1. Voltmeter
2. Voltage Control
3. Wire Speed Meter
4. Wire Speed Control
2 4

Performance Data

Duty Cycle Chart Volt/Amp Curves

500 35
450
400
350 30 Max
300
250 25
Weld Amps

200
20
Volts

150
15 Min

100 10

50 0
10 20 30 40 50 60 70 80 90 100 0 100 200 300 400

% Duty Cycle Amperes

2
Standard Fully Loaded Features

EZ-Change™ low cylinder rack

Operators no longer need to lift cylinders.
Cylinders now easily roll on and off our
EZ-Change™ low cylinder rack.

Angled wire drive

Angled industrial aluminum dual-gear
drive system significantly improves wire
feeding and runs large spools of wire.
Allows quick change of drive rolls
without tools.
Drive roll storage — no more lost drive
rolls, extra drive rolls are conveniently
stored next to drive motor.
Operators no longer bump into and bend
MIG gun and gun liner.

Dual front handles

Split handle with rubber grips designed
to move machine easily and allow
work lead and MIG gun to be stored
independently.
Handles provide protection for front panel
and MIG gun during transportation.

EZ-Access™ consumable
compartment and
parameter chart
Convenient flip-down compartment
holds parameter chart and storage for
consumables.

Auto-Gun Detect™
Simply pull the trigger for either the MIG,
spool gun or any Miller® push-pull gun.
The Millermatic 252 automatically recalls
voltage, wire feed speed and timer of the
active gun.
Reduces setup time!

3
 Optional Fully Loaded Features

Elevated gun and cable rack

300335
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
No more running over spool gun cables
or cables dragging on the floor.
Elevated gun and cable rack can be
used with either a single or dual cylinder
rack. (Elevated gun and cable rack is
included with the dual EZ-Change™ low
cylinder rack.)

Dual EZ-Change™ low cylinder

rack with elevated gun and
cable rack
300337
Dual cylinder rack allows for easy
storage of two cylinders.
EZ-Change™ low cylinder rack eliminates
the need to lift cylinders on and off
cylinder rack.
No more running over spool gun cables
or cables dragging on the floor.
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.

4
 Genuine Miller Accessories ®

Push-Pull Guns M-25 Replacement Gun

169594 10 ft. (3 m)
Direct connection for Miller push-pull guns. 169596 12 ft. (3.7 m)
Able to utilize 12-inch rolls of aluminum wire 169598 15 ft. (4.6 m) standard
inside the Millermatic 252 for extended Gun shipped to run .030–.035 inch
aluminum welding time. (0.8–0.9 mm) wire.
Wire feed speed is adjustable at the gun and
actual speed can be seen on the digital
display on the Millermatic 252.
Adjustable run-in control to fine tune
arc starting.

XR-Aluma-Pro™ Lite Push-Pull Gun Spoolmatic® 15A Spool Gun 195156

300948 25 ft. (7.6 m) Spoolmatic® 30A Spool Gun 130831
Air-cooled gooseneck-style gun for .030–.047 in. Ideal for aluminum welding jobs. Air-cooled, Dual EZ-Change™ Low Cylinder Rack with
(0.8–1.2 mm) aluminum. Rated at 175 amps at one-pound spool gun with 15-foot (4.6 m) Elevated Gun and Cable Rack 300337
60 percent duty cycle. or 30-foot (9.1 m) cable assembly. Rated at Dual cylinder rack allows operators to easily roll
200 amps at 100 percent duty cycle. For cylinders on and off the rack with no lifting. Gun
detailed information, see Spoolmatic literature and cable rack keeps cables off the floor and
M/1.73. tangle free.

XR-Aluma-Pro™ Push-Pull Gun Elevated Gun and Cable Rack 300335

300000 15 ft. (4.6 m) For use with single cylinder rack. (Included with
300001 25 ft. (7.6 m) dual EZ-Change low cylinder rack.)
Air-cooled gooseneck-style gun for .030–.047 in.
(0.8–1.2 mm) aluminum. Rated at 200 amps at
100 percent duty cycle.

Spoolmate™ 200 Spool Gun 300497

Reliable and economical spool gun perfect
XR™-Pistol Push-Pull Gun for hobbyists and light fabricators who
198127 15 ft. (4.6 m) cable weld aluminum. Handles .030–.035 inch
198128 30 ft. (9 m) cable (0.8–0.9 mm) aluminum wires and
Air-cooled pistol grip gun for .030–.047 in. .023–.035 inch (0.6–0.9 mm) steel/stainless
(0.8–1.2 mm) aluminum. Rated at 200 amps at steel wires. Rated at 160 amps, 60 percent duty
cycle with 20-foot cable assembly. For detailed Protective Cover 195142
100 percent duty cycle. Features side pocket.
information, see Spoolmate literature M/1.47.
(Not for use with dual cylinder rack or elevated
U-Grooved Aluminum Drive Roll and gun and cable rack.)
Accessory Kits for Push-Pull Guns
Note: XR-Aluma-Pro kits include Millermatic U-grooved Argon/Mixed Gas Regulator and Gas Hose
drive rolls, nylon wire guides and contact tips.
195050
XR-Pistol kits include Millermatic U-grooved drive rolls,
nylon wire guides, gun drive rolls and contact tips. (Order from Miller Service Parts.)
For XR-Aluma-Pro (air-cooled)
195311 .035 in. (0.9 mm)
195312 .040 in. (1 mm)
195313 .047 in. (1.2 mm)
For XR Pistol (air-cooled)
195201 .035 in. (0.9 mm)
195273 .040 in. (1 mm)
195202 .047 in. (1.2 mm)

5
 Consumables (Order from Miller Service Parts.)
Millermatic® Drive Roll Kits
Note: Drive roll kits include two drive rolls and an
inlet guide.
V-Grooved Drive Roll Kits (solid wire)
204579 .030 and .035 in.
(0.8 and 0.9 mm)
combination (reversible)
087131 .024 in. (0.6 mm) M-Series Consumable Kits
079594 .030 in. (0.8 mm) 234610 .030 in. (0.8 mm)
079595 .035 in. (0.9 mm) 234611 .035 in. (0.9 mm)
079596 .045 in. (1.2 mm) 234612 .045 in. (1.2 mm)
V-Knurled Drive Roll Kits Contains ten contact tips, one nozzle, one
(flux-cored or difficult-to-feed wire) Nozzles contact tip adapter and one nozzle adapter.
079606 .035 in. (0.9 mm) Note: Flush or stickout nozzles should be used for
the short-circuit process. Recessed nozzles should be
079607 .045 in. (1.2 mm)
used for the spray arc process.
U-Grooved Drive Roll Kits 200258 (standard)
(aluminum wire) 1/2-inch (13 mm) diameter orifice. Nozzle flush
044749 .035 in. (0.9 mm) with contact tip.
079599 .047 in. (1.2 mm)
169726
5/8-inch (16 mm) diameter orifice. Nozzle flush
with contact tip.
For M-25 Gun
169727
5/8-inch (16 mm) diameter orifice. Contact tip
sticks out of nozzle 1/8 inch (3.2 mm).
Contact Tips 169724
087299 .024 in. (0.6 mm) 1/2-inch (13 mm) diameter orifice. Contact tip
000067 .030 in. (0.8 mm) recessed 1/8 inch (3.2 mm) into nozzle.
000068 .035 in. (0.9 mm) 169725
000069 .045 in. (1.2 mm) 5/8-inch (16 mm) diameter orifice. Contact tip
187117 .035 in. (0.9 mm) heavy-duty tip recessed 1/8 inch (3.2 mm) into nozzle.
187118 .045 in. (1.2 mm) heavy-duty tip
Tapered Nozzles
Tapered Contact Tips Note: Tapered tips are recommended when using a
176797 .030 in. (0.8 mm) tapered nozzle.
176793 .035 in. (0.9 mm)
176243
176794 .045 in. (1.2 mm)
3/8-inch (9.5 mm) diameter orifice.
178386
11/32-inch (8.7 mm) diameter orifice.

Nozzle Adapter 169729

Contact Tip Adapter 169728

Replacement Liners
194010 .024 in.
194011 .030–.035 in. (standard)
194012 .035–.045 in.
15-foot length — trim to size needed.

6
 Ordering Information
Steel Configuration Stock No. Description Qty. Price
Millermatic® 252 907321 200(208)/230 V, 60 Hz
907322 230/460/575 V, 60 Hz
Millermatic V-Grooved Drive Roll Kits (solid wire) 087131 .024 in. (0.6 mm)
079594 .030 in. (0.8 mm)
079595 .035 in.(0.9 mm)
079596 .045 in.(1.2 mm)
Millermatic V-Knurled Drive Roll Kits (flux-cored) 079606 .035 in. (0.9 mm)
079607 .045 in. (1.2 mm)
Contact Tips (10 per package) 087299 .024 in. (0.6 mm)
000067 .030 in. (0.8 mm)
000068 .035 in. (0.9 mm)
000069 .045 in. (1.2 mm)
Nozzles 200258 1/2 in. (13 mm) diameter, flush (included with standard configuration)
169726 5/8 in. (16 mm) diameter, flush
169727 5/8 in. (16 mm) diameter, 1/8 in. (3.2 mm) exposed
169724 1/2 in. (13 mm) diameter, 1/8 in. (3.2 mm) recessed
169725 5/8 in. (16 mm) diameter, 1/8 in. (3.2 mm) recessed
M-Series Gun Consumable Kits (for M-25) 234610 .030 in. (0.8 mm)
234611 .035 in. (0.9 mm)
234612 .045 in. (1.2 mm)

Aluminum Configuration (Spool Gun) For M-25 gun consumables and non-aluminum Millermatic 252 drive rolls, see steel configuration chart above.
Millermatic® 252 Spool Gun Packages 951066 200(208)/230 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
(includes standard M-25 MIG gun) elevated gun and cable rack, regulator and hose
951065 230/460/575 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
elevated gun and cable rack, regulator and hose
Spoolmatic Contact Tips (10 per package) 206187 .035 in. (0.9 mm)
206188 .040 in. (1.0 mm)
206189 .047 in. (1.2 mm)
Spoolmatic Nozzles 198855 5/8 in. (16 mm) diameter
199618 5/8 in. (16 mm) diameter, HD
199616 3/4 in. (19 mm) diameter
199617 3/4 in. (19 mm) diameter, HD

Aluminum Configuration (Push-Pull Gun) For M-25 gun consumables and non-aluminum Millermatic 252 drive rolls, see steel configuration chart above.
Millermatic 252
® 907321 200(208)/230 V, 60 Hz
(includes standard M-25 MIG gun) 907322 230/460/575 V, 60 Hz
XR-Aluma-Pro™ Lite Gun (air-cooled) 300948 25 ft. (7.6 m)
XR-Aluma-Pro Gun (air-cooled)
™ 300000 15 ft. (4.6 m)
300001 25 ft. (7.6 m)
XR™-Pistol (air-cooled) 198127 15 ft. (4.6 m)
198128 30 ft. (9.1 m)
Millermatic U-Grooved Drive Roll Kits (aluminum) 044749 .035 in. (0.9 mm)
079599 .047 in. (1.2 mm)
XR-Aluma-Pro U-Grooved Drive Roll Kits 195311 .035 in. (0.9 mm)
(required, includes Millermatic U-Grooved Drive Roll Kit) 195312 .040 in. (1.0 mm)
195313 .047 in. (1.2 mm)
XR-Pistol U-Grooved Drive Roll Kits 195201 .035 in. (0.9 mm)
(required, includes Millermatic U-Grooved Drive Roll Kit) 195273 .040 in. (1.0 mm)
195202 .047 in. (1.2 mm)
XR-Aluma-Pro Lite Contact Tips (10 per package) T-035AL .035 in. (0.9 mm)
T-047AL .047 in. (1.2 mm)
XR-Aluma-Pro and XR-Pistol Contact Tips (10 per package) 206187 .035 in. (0.9 mm)
206188 .040 in. (1.0 mm)
206189 .047 in. (1.2 mm)
Nozzles 198855 5/8 in. (16 mm) diameter
199618 5/8 in. (16 mm) diameter, HD
199616 3/4 in. (19 mm) diameter
199617 3/4 in. (19 mm) diameter, HD

Date: Total Quoted Price:

7
 Ordering Information
Accessories Stock No. Description Qty. Price

XR-Aluma-Pro™ Lite Gun (air-cooled) 300948 25 ft. (7.6 m)

™
XR-Aluma-Pro Gun (air-cooled) 300000 15 ft. (4.6 m)
300001 25 ft. (7.6 m)
XR™-Pistol Gun (air-cooled) 198127 15 ft. (4.6 m)
198128 30 ft. (9 m)
M-25 Gun 169594 10 ft. (3 m), .023–.035 in. (0.6–0.9 mm)
169596 12 ft. (3.7 m), .023–.035 in. (0.6–0.9 mm)
169598 15 ft. (4.6 m), .023–.035 in. (0.6–0.9 mm)
Spoolmatic® 15A 195156 15 ft. (4.6 m), 200 A, .023–1/16 in. (0.6–1.6 mm) for aluminum
Spoolmatic® 30A 130831 30 ft. (9 m), 200 A, .023–1/16 in. (0.6–1.6 mm) for aluminum
Spoolmate™ 200 300497 20 ft. (6 m), 160 A, .030–.035 in. (0.8–0.9 mm) for aluminum,
.023–.035 in. (0.6–0.9 mm) for steel/stainless steel wires
Optional Spoolmate 200 Barrel Assemblies 300591 45-degree barrel
300592 9 in. extension barrel
300593 Heavy-duty barrel
Dual EZ-Change™ Low Cylinder Rack with 300337
Elevated Gun and Cable Rack
Elevated Gun and Cable Rack 300335 For use with single cylinder rack
(included with dual EZ-Change low cylinder rack)
Protective Cover 195142 Features side pocket
Argon/Mixed Gas Regulator and Gas Hose 195050

Date: Total Quoted Price:

Note: See page 7 for ordering information on the Millermatic 252 — available packages, steel and aluminum configurations, and drive roll kits/consumables.

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© 2016 Miller Electric Mfg. Co.