Miller MigMatic 300 Owner's Manual
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Miller MigMatic 300 Owner's Manual

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MigMatic 300/380 And DX
OWNER'S MANUAL
OM-251958F
Processes
Description
Arc Welding Power Source
Wire Feeder
R
CE
2018-02
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
File: MIG (GMAW)

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Summary of Contents for Miller MigMatic 300

  • Page 1 OM-251958F 2018-02 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Wire Feeder MigMatic 300/380 And DX OWNER’S MANUAL File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ....... 5-5. Trigger Mode And Spot Time Selection (MigMatic 300 And 380 Models) .

  • Page 4: Declaration Of Conformity

    Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number MIGMATIC 300, 400VAC 029015540 MIGMATIC 300 DX, 400VAC 029015541 MIGMATIC 300, 230/400VAC 029015545 MIGMATIC 300 DX, 230/400VAC 029015546 MIGMATIC 380, 400VAC...
  • Page 5 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MIGMATIC 380, 400VAC 029015542 MIGMATIC 380 DX, 400VAC 029015543 MIGMATIC 380, 230/400VAC 029015547 MIGMATIC 380 DX, 230/400VAC 029015548 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822−...
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MIGMATIC 300, 400VAC 029015540 MIGMATIC 300 DX, 400VAC 029015541 MIGMATIC 300, 230/400VAC 029015545 MIGMATIC 300 DX, 230/400VAC 029015546 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 10: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 11: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 12 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012−05 Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Disconnect input plug or power before working on machine.

  • Page 13: Miscellaneous Symbols And Definitions

    Move jumper links as shown on inside label to match input voltage at job site. Include extra length in grounding conductor and connect grounding conductor first. Connect line input conductors as shown on inside label. Double-check all connections, jumper link positions, and input voltage before applying power.

  • Page 14: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the 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. 3-2.

  • Page 15: Volt-Ampere Curves

    The volt-ampere curves show the normal minimum and maximum volt- age and amperage output capabili- ties of the welding power source. Curves of other settings fall between the curves shown. MigMatic 300 DC Amperes MigMatic 380 DC Amperes OM-251958 Page 9...

  • Page 16: Environmental Specifications

    3-5. Environmental Specifications A. IP Rating IP Rating IP22S This equipment is designed for indoor use and is not intended to be used or stored outside. IP22S 2014−06 B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range −10 to 40°C (14 to 104°F) −20 to 55°C (−4 to 131°F) *Output is derated at temperatures above 40°C (104°F).

  • Page 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve.

  • Page 18: Installing Wire Spool And Adjusting Hub Tension

    4-2. Installing Wire Spool And Adjusting Hub Tension Spacers Use only for 5Kg spool. Hub Assembly 15 Kg Wire Spool 5 Kg Wire Spool Assembly Assembly Tools Needed: Ref. D2 OM-251958 Page 12...

  • Page 19: Positioning Jumper Links (230/400V 3-Phase Models)

    4-3. Positioning Jumper Links (230/400V 3-Phase Models) Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal lockout/tagout devices. Check input voltage available at site. Jumper Link Label 230 Volts 400 Volts Check label −...

  • Page 20: Electrical Service Guide

    4-4. Electrical Service Guide Elec Serv 2017-01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 21 Notes OM-251958 Page 15...

  • Page 22: Connecting 3-Phase Input Power

    4-5. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: input2 2012−05 − Ref. 803766-C / Ref. 956142845_5_14_A OM-251958 Page 16...
  • Page 23 4-5. Connecting 3-Phase Input Power (Continued) See rating label on unit and check input volt- Connect green or green/yellow grounding Installation must meet all National and age available at site. conductor to disconnect device grounding ter- Local Codes − have only qualified per- minal first.

  • Page 24: Changing Drive Rolls And Wire Inlet Guide (Migmatic 380 Models)

    4-6. Changing Drive Rolls And Wire Inlet Guide (MigMatic 380 Models) Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two different sized grooves.
  • Page 25 4-6. Changing Drive Rolls And Wire Inlet Guide (MigMatic 300 Models) (Continued) Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two...

  • Page 26: Aligning Drive Rolls And Wire Guide

    4-7. Aligning Drive Rolls and Wire Guide Turn off and disconnect in- put power View is from top of drive rolls looking down with pressure assembly open. Correct Incorrect Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

  • Page 27: Threading Welding Wire And Adjusting Pressure Roll Tension

    4-8. Threading Welding Wire And Adjusting Pressure Roll Tension Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling.

  • Page 28: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls For MigMatic 300 Power Switch S1 Use switch to turn power on and off. Voltage Range Control S2 Allows selection of voltage in two coarse ranges, A or B. Voltage Adjustment Control S3 This control allows for 10 voltage settings in each of the two coarse voltage ranges (A or B) of S2.

  • Page 29: Controls For Migmatic 380

    5-2. Controls For MigMatic 380 Power Switch S1 Use switch to turn power on and off. Voltage Range Control S2 Allows selection of voltage in three coarse ranges, A, B or C. Voltage Adjustment Control S3 This control allows for 10 voltage settings in each of the three coarse voltage ranges (A, B or C) of S2.

  • Page 30: Selecting Parameters (Migmatic 300 And 380 Models)

    5-3. Selecting Parameters (MigMatic 300 And 380 Models) Parameter LEDs Digital Display Meter D1 Setup Button P1 To select welding parameters, pro- ceed as follows: Press and release P1 push button to select desired parameter (V, A, or %) and the corresponding LED will light up.

  • Page 31: Sequencer Controls Settings (Migmatic 300 And 380 Models)

    5-4. Sequencer Controls Settings (MigMatic 300 And 380 Models) Sequencer Control LEDs Digital Display Meter D1 Setup Button P1 Parameter LED S (Seconds) Wire Feed Speed Control R1 Setup Menu LED To enter Sequencer Control set-up mode and scroll through parameters, press and hold for three seconds the Setup button P1.

  • Page 32: Trigger Mode And Spot Time Selection (Migmatic 300 And 380 Models)

    5-5. Trigger Mode And Spot Time Selection (MigMatic 300 And 380 Models) Always select a trigger mode. Digital Display Meter D1 Trigger Mode Selection Button To select trigger mode and spot weld timer, proceed as follows: Press and release P2 push button.

  • Page 33: Welding Wire Loading Settings (Migmatic 300 And 380 Models)

    5-6. Welding Wire Loading Settings (MigMatic 300 And 380 Models) Setup Button P1 Prepare unit for welding wire load- ing as follows: S Install wire spool and adjust hub tension (see Section 4-2). S Use proper drive rolls and wire guide (see Section 4-6).

  • Page 34: Resetting Unit To Factory Default Settings (Migmatic 300 And 380 Models)

    5-7. Resetting Unit To Factory Default Settings (MigMatic 300 And 380 Models) This procedure will delete all oper- ator specified parameters, and re- call all factory parameters. Trigger Mode Selector Switch P2 Press and hold P2 button, and factory defaults will be restored.

  • Page 35: Controls For Migmatic 300Dx

    5-8. Controls For MigMatic 300DX Power Switch S1 Use switch to turn power on and off. Voltage Range Control S2 Allows selection of voltage in two coarse ranges, A or B. Voltage Adjustment Control S3 This control allows for 10 voltage settings in each of the two coarse voltage ranges (A or B) of S2.

  • Page 36: Controls For Migmatic 380Dx

    5-9. Controls For MigMatic 380DX Power Switch S1 Use switch to turn power on and off. Voltage Range Control S3 Allows selection of voltage in three coarse ranges, A, B or C. Voltage Adjustment Control S2 This control allows for 10 voltage settings in each of the three coarse voltage ranges (A, B or C) of S2.

  • Page 37: Burnback And Run-In Controls (Dx Models Only)

    5-10. Burnback And Run-In Controls (DX Models Only) Burnback Control R3 Use control to set time welding wire stays energized after trigger is re- leased. Wire Run-In Speed Control Use control to determine rate at which welding wire feeds before an arc is initiated.

  • Page 38: Welding Power Source Input Line Voltage Adjustment (Dx Models Only)

    5-11. Welding Power Source Input Line Voltage Adjustment (DX Models Only) Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Wire Feed Speed Indicator Scale (Manual Mode) Input Line Voltage Adjustment Center Indicator (Synergic Mode) Input Line Voltage/Wire Speed Adjustment Indicator Scale (Synergic Mode) Before power up, turn control R1 to the...

  • Page 39: Welding Power Source Setup Menu (Dx Models Only)

    5-12. Welding Power Source Setup Menu (DX Models Only) Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Synergic Mode Indicator Voltage LED Digital Display Meter Amperage LED Wire Feed Speed LED Setup Button Manual Mode Indicator Voltage Control 10 Trigger Mode Button Use setup button to select desired...

  • Page 40: Trigger Mode Selection (Dx Models Only)

    5-13. Trigger Mode Selection (DX Models Only) Always select a trigger mode. 2-t Trigger Mode When trigger is pressed welding starts. When trigger is released, welding stops. 4-t Trigger Mode When trigger is pressed, welding starts. When trigger is released, welding contin- ues.

  • Page 41: Welding Wire Type Selection For Synergic Mig (Dx Models Only)

    5-15. Welding Wire Type Selection For Synergic MIG (DX Models Only) Welding Wire Types Welding Wire Type Button Press button to select desired wire type: Fe (ferris), CrNi (stainless steel), Al (aluminum), or CuSi (Cop- per Silicon), and lite corresponding LED.

  • Page 42: Selecting Manual Mig Welding (Dx Models Only)

    5-17. Selecting Manual MIG Welding (DX Models Only) Setup Button Manual MIG Mode Indicator Press and hold setup button for ap- proximately 3 seconds to select manual MG mode and light the in- dicator. Voltage Control S2 Wire Feed Speed (WFS)/Trim (Arc Length) And Line Input Adjustment Control R1 Digital Display Meter...

  • Page 43: Selecting Synergic Mig Welding (Dx Models Only)

    5-18. Selecting Synergic MIG Welding (DX Models Only) Setup Button Synergic MIG Mode Indicator Press and hold setup button for ap- proximately 3 seconds to select synergic MIG mode and light up the indicator. Voltage Control S2 Wire Feed Speed (WFS/Trim (Arc Length) And Line Input Adjustment Control R1 Digital Display Meter...

  • Page 44: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 45: Troubleshooting

    6-4. Troubleshooting Trouble Remedy Be sure line disconnect switch is On (see Section 4-5). No weld output; wire does not feed. Replace building line fuse or reset circuit breaker if open (see Section 4-5). Secure gun trigger connections. Check continuity of power switch S1 and replace if necessary. Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure.

  • Page 46: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 956142850-B Figure 7-1. Circuit Diagram for Migmatic 300 (230/400 VAC) OM-251958 Page 40...
  • Page 47 956142846-B Figure 7-2. Circuit Diagram for Migmatic 300 (400 VAC) OM-251958 Page 41...
  • Page 48 956142852-B Figure 7-3. Circuit Diagram for Migmatic 380 (230/400 VAC) OM-251958 Page 42...
  • Page 49 956142848-B Figure 7-4. Circuit Diagram for Migmatic 380 (400 VAC) OM-251958 Page 43...
  • Page 50 956142851-C Figure 7-5. Circuit Diagram for Migmatic 300 DX (230/400 VAC) OM-251958 Page 44...
  • Page 51 956142847-C Figure 7-6. Circuit Diagram for Migmatic 300 DX (400 VAC) OM-251958 Page 45...
  • Page 52 956142853-C Figure 7-7. Circuit Diagram for Migmatic 380 DX (230/400 VAC) OM-251958 Page 46...
  • Page 53 956142849-C Figure 7-8. Circuit Diagram for Migmatic 380 DX (400 VAC) OM-251958 Page 47...

  • Page 54: Section 8 − Parts List

    SECTION 8 − PARTS LIST 956142845_11_14_A Figure 8-1. Wrapper Assembly, MigMatic 300/380 Item Part Description Quantity Model Figure 8-1. Wrapper Assembly, MigMatic 300/380 ..156034005 Latch, Side Panel ..........
  • Page 55 Item Part Description Quantity Model Figure 8-1. Wrapper Assembly, MigMatic 300/380 ..156012152 Axle, Wheel Rear D.20 L.471 ........
  • Page 56 956142845_13_14_B Figure 8-2. Main Assembly, MigMatic 300 Quantity Model Item Dia. Part 230/400 400 Mkgs. Description Figure 8-2. Main Assembly, MigMatic 300 ....156012138 Spool Holder, Shaft .
  • Page 57 Dia. Part 230/400 400 Mkgs. Description Figure 8-2. Main Assembly, MigMatic 300 ....+178937 Label, Warning Electric Shock ......
  • Page 58 ... 356029240 Nameplate, Fuse, MigMatic 300/380 ......
  • Page 59 ....356029239 Nameplate, Rear, MigMatic 300/380 Base/DX ....
  • Page 60 956142845_11_14_A Figure 8-4. Wrapper Assembly, MigMatic 300DX/380DX Item Part Description Quantity Model Figure 8-4. Wrapper Assembly, MigMatic 300DX/380DX ..156034005 Latch, Side Panel ..........
  • Page 61 Item Part Description Quantity Model Figure 8-4. Wrapper Assembly, MigMatic 300/380 ..156012152 Axle, Wheel Rear D.20 L.471 ........
  • Page 62 956142845_14_14_B Figure 8-5. Main Assembly, MigMatic 300DX Quantity Model Item Dia. Part 230/400 400 Mkgs. Description Figure 8-5. Main Assembly, MigMatic 300DX ....156012138 Spool Holder, Shaft .
  • Page 63 ....356029239 Nameplate, Rear, MigMatic 300/380 Base/DX ....
  • Page 64 956142845_14_14_B Figure 8-6. Main Assembly, MigMatic 380DX Quantity Model Item Dia. Part 230/400 400 Mkgs. Description Figure 8-6. Main Assembly, MigMatic 380DX ....156012138 Spool Holder, Shaft .
  • Page 65 ....356029239 Nameplate, Rear, MigMatic 300/380 Base/DX ....
  • Page 66 See Table 7-1 Drive Roll And Wire Guide Kits Hardware is common and not available unless listed. 956142845_9_14_A Figure 8-7. Drive Assembly, Wire (2 Roll) Item Dia. Part Mkgs. Description Quantity Figure 8-7. Drive Assembly, Wire (2 Roll) ..
  • Page 67 Item Dia. Part Mkgs. Description Quantity Figure 8-7. Drive Assembly, Wire (2 Roll) ... . . 079634 Pin, Hinge .............
  • Page 68 See Table 7-2 Drive Roll And Wire Guide Kits Hardware is common and not available unless listed. 956142845_10_14_B Figure 8-8. Drive Assembly, Wire (4 Roll) Item Dia. Part Mkgs. Description Quantity Figure 8-8. Drive Assembly, Wire (4 Roll) ..
  • Page 69 Item Dia. Part Mkgs. Description Quantity Figure 8-8. Drive Assembly, Wire (4 Roll) ... . . 010224 Pin, Spring CS .187 x 1.000 ..........
  • Page 70 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.
  • Page 71 Effective January 1, 2018 (Equipment with a serial number preface of MJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 72 File a claim for loss or damage during Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 shipment. email: miller@itw−welding.it For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2018 Miller Electric Mfg. LLC 2018−01...

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