251 wire feed problem

[jeromewaybrown]

My Millermatic 251 wire feed will only start the roll drive at its lowest speed setting, if I continue to press the trigger it will speed up when I adjust the speed. If I try to start the drive at a higher speed I get a HL.P 005 error message. I removed the wire and drive roll, and checked the connections but still have the same problem.

This is my hobby welder and it has very little use (still on my first spool of wire). I took off the cover and it is very clean inside with no evidence of mice etc.

Could it be the motor or gear box? Should I disassemble clean and re-lube? Or is it the board?

[SundownIII]

Jerome,

Don't have access to the error codes for the MM251.

The P5 code on the tig machines is generally related to heat in the transformer. This, most likely, is not the problem you're experiencing.

I'm assuming that the machine is relatively new to you and that it is being operated in a "new" location.

First thing I'd check is my input power. Does the circuit provide adequate ampherage to run the system at max output.

The starting input for that machine is considerably higher than the running amps. If you're starving it for power it may not be enough to trip a circuit breaker but the machine may sense a voltage/amp shortfall.

If you've got good juice to the machine, I'm more inclined to think control board than I am a drive motor.

[griff01]

My Millermatic 251 wire feed will only start the roll drive at its lowest speed setting, if I continue to press the trigger it will speed up when I adjust the speed. If I try to start the drive at a higher speed I get a HL.P 005 error message. I removed the wire and drive roll, and checked the connections but still have the same problem.

This is my hobby welder and it has very little use (still on my first spool of wire). I took off the cover and it is very clean inside with no evidence of mice etc.

Could it be the motor or gear box? Should I disassemble clean and re-lube? Or is it the board?

This may not be much help but:

HL.P 005 − Wire feed malfunction. Check
wire feed delivery system (see Section
6-8).
See Section 6-8 for additional information

Note: Section 6-8 isn't any help. It says for hl.p 005 there is a wire feed delivery problem.
You already knew that.

Griff

[crawler]

Call Miller tech support. 1800 4A Miller

[jeromewaybrown]

Thanks for the responses

The machine has been working at the same spot and power supply since it was new. It has plenty of voltage if I remember right, it is 224 volts that I checked this morning. Yes I will try to call Miller tomorrow. Thanks for the input!

[ccawgc]

try feeding wire with the pressure roller released.
Try feeding wire with the gun removed.
Back the drive roll on the motor shaft off.
Two possible faults. Bad liner. bent or rusty. and the drive roll pushed in and jamming on the drive housing. Remove drive roll and put snap ring and spring washers back in the right place. install roller and tighten screw until groove is centered on wire. Replace liner do not trim to short.

[cruizer]

Try disconnecting the gun trigger from the machine, flip the drive tentioner open and paper clipping the trigger terminals. likely have a gun trigger to internal conduit fault. Might want to test the trigger wires. There is a spare wire in there for problems like this.

Lincolns say "Too Hot", Millers say help 5, same condition though.

[jeromewaybrown]

Status

I contacted Miller service. Since with my meter I can catch up to a 2 amp draw on the motor, the service tech thought the problem is with the motor. I ordered a new motor/gear box and I should be able to pick it up today. $150+.

Since then I tried the above test eliminating the trigger on the gun and jumping the connections. Same 005 error.

I removed the motor/gear box and opened the gear box cover. The gear box is simply a metal worm gear attached to the motor that drives a plastic fiber gear. I removed the plastic sprocket and used the jumper to activate the trigger. Same 005 error.

I unhooked the motor 24volt connections and triggered with the gun. No error.

I am hoping that I have isolated the problem to the motor. I'll post again when I receive and install the new motor gear box.

[aametalmaster]

I ordered a new motor/gear box and I should be able to pick it up today. $150+.

And you are on your first roll of wire. That's just wrong paying that much...Bob

[jeromewaybrown]

Darn!

The motor/gear box did not solve the problem!!!!
I still have the same problem! 005 fault when trying to run the feed motor unhooked from welding wire, feed roll, etc.

Does anyone know what pots 1, 2 and 3 do on the drive board? I thought they might be excel and decel ramps. But adjusting each of them one at a time 2 turns up and 2 turns down did not help the problem.

Please anyone with any ideas let me know!!!!

[cruizer]

Honestly didn't think it would but you never know...

Did you indeed completely unplug the gun connector from the machine?, I mean often there is an adaptor from the gun to the machine. This connector /adaptor really likes to fail.

On that 4 pin connector on the machine, did you jumper pins 1 & 2 with the drive tensioner off, and/ or gun completely removed from the machine?

[jeromewaybrown]

Honestly didn't think it would but you never know...

Did you indeed completely unplug the gun connector from the machine?, I mean often there is an adaptor from the gun to the machine. This connector /adaptor really likes to fail.

On that 4 pin connector on the machine, did you jumper pins 1 & 2 with the drive tensioner off, and/ or gun completely removed from the machine?

Cruizer;
I unscrewed the gun connector from the front of the machine and jumpered the pins there.
I have been testing with the motor and gear box removed from the machine(but wired up). So there is no way the drive tensioner, the liner or welding wire or any other mechanical thing is putting a bind on the motor.

Thanks for the Help!