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Miller TRUE BLUE MigMatic 260i Owner's Manual

Arc welding power source wire feeder
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MigMatic 260i/300iP/320i
OWNER'S MANUAL
OM-287348A
Processes
Description
Arc Welding Power Source
Wire Feeder
R
CE
2020-04
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
File: MIG (GMAW)

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Summary of Contents for Miller TRUE BLUE MigMatic 260i

  • Page 1 OM-287348A 2020-04 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Wire Feeder MigMatic 260i/300iP/320i 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MigMatic 260i 059015051 MigMatic 300iP 059015052 MigMatic 320i 059015053 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822−1:2016, IEC 62822−2:2016 Intended use for occupational use for use by laymen...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 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 Hazards 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 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. Safe30 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation −...
  • Page 13 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: Miscellaneous Symbols And Definitions

    2-2. Miscellaneous Symbols And Definitions Maximum Amperage Effective Settings 1eff Supply Current Conventional Volts Fuse Load Voltage Alternating Rated Welding Gas Type Current (AC) Current Direct Current Duty Cycle Voltage Input (DC) Remote Percent Wire Feed Rated No Load Hertz Voltage (OCV) Degree Of Input...

  • Page 15: Section 3 − Specifications

    3-3. Information About Default Weld Parameters And Settings NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 16: Duty Cycle And Overheating

    3-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated MigMatic 320i load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

  • Page 17: Volt-Ampere Curves

    3-7. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage MIGMATIC 260i and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. DC Amperes MIGMATIC 300iP DC Amperes MIGMATIC 320i DC Amperes OM-287348 Page 11...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 19: Installing Gas Supply

    4-3. 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. Close valve.

  • Page 20: Installing Wire Spool And Adjusting Hub Tension

    4-4. Installing Wire Spool And Adjusting Hub Tension Spacers Use only for 5 kg (11 lb) spool. Hub Assembly 15 Kg (33 lb) 5 Kg (11 lb) Wire Spool Wire Spool Assembly Assembly Tools Needed: Ref. D2 OM-287348 Page 14...

  • Page 21: Remote 14-Pin Receptacle Information

    4-5. Remote 14-Pin Receptacle Information Socket Socket Information OUTPUT CONTACTOR +5V Pot INPUT/OUTPUT Comm Pot1-2 REMOTE Down1/R Pot1 CONTROL POT 1 +5V Pot C L N Comm Pot1-2 Down2/R Pot2 INPUT/OUTPUT REMOTE CONTROL POT 2 Common sense Sense 2 (R220K Pot 2) Comm Pot1-2 Down1/R Pot1 UP/DOWN TORCH...

  • Page 22: Electrical Service Guide (Three-Phase)

    4-6. Electrical Service Guide (Three-Phase) Elec Serv 2019−10 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 23: Connecting 3-Phase Input Power

    4-7. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: input2 2012−05 − Ref. 803766-C / Ref. 956172373_3_A OM-287348 Page 17...
  • Page 24 4-7. 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 25: Changing Drive Rolls And Wire Inlet Guide

    4-8. Changing Drive Rolls And Wire Inlet Guide Drive Roll Securing Screw Drive Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. The drive roll consists of two different sized grooves. stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll.

  • Page 26: Aligning Drive Rolls And Wire Guide

    4-9. 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

    4-10. 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. Front And Rear Panel Controls Power Switch S1 LCD Home Screen Allows to select desired unit settings. Use switch to turn power on and off. Output ON Indicator LED 11 MIG Torch Connection Voltage Control Knob Connection for Euro style MIG gun.

  • Page 29: Side Panel Controls

    5-2. Side Panel Controls Gas Purge Switch Press gas purge switch to energize gas valve to purge air from gun or adjust gas regulator. Wire Inch Control Switch Use inch position to momentarily feed welding wire at speed set on wire speed control without energizing welding circuit or shielding gas valve.

  • Page 30: Display User Interface

    5-3. Display User Interface LCD Home Screen Process/Home Soft Key Press key to enter the welding process menu screen. For more information, see Section 5-7. Sequence Parameter Soft Key Press key to enter the welding pa- rameter setup screen. For more in- formation, see Section 5-6 and 5-7.

  • Page 31: Trigger Mode Selection

    5-4. Trigger Mode Selection Voltage selected. When trigger is pressed, pre-gas rent level. When trigger is released, welding See section 5-5 for more trigger flow starts. When trigger is released, wire current decreases to the pre-set welding cur- operations. feed starts with pre-set wire Run-In control. rent.

  • Page 32: Trigger Operations

    5-5. Trigger Operations Amps MIG 2T Slope Down Time Slope Up Time Min= 0.1 sec Min= 0.1 sec Max=10.0 sec Max=2.0 sec Welding Current Burn-Back Run-In (%) Min= 5% Min= 15% Max=200% Max=125% Pre-Gas Time Post-Gas Time Min= 0.1 sec Min= 0.1 sec Max=2.0 sec Max=15.0 sec...

  • Page 33: Trigger Parameter Settings

    5-6. Trigger Parameter Settings 2T Trigger Settings Arc Length 4T Trigger Settings Arc Length 4TS Trigger Settings 11 8 8 Arc Length Stitch Trigger Settings Arc Length 956172373_11-A OM-287348 Page 27...
  • Page 34 5-6. Trigger Parameter Settings (Continued) Trigger Mode Soft Key ter settings. Use knob to adjust parameter to final amperage. To disable, set to 0. (Min= value. Use sequence parameter soft key to 0.1s, max= 10s). Parameter Settings Soft Key scroll through sequencer. The following Gas Post-flow LED Press key to enter the trigger parameter set- parameters will be displayed.

  • Page 35: Variable Inductance Settings

    5-7. Variable Inductance Settings Turn knob to adjust value Voltage Press to return Press to to home screen continue Press to Press to continue return to home screen Parameter Settings Soft Key again to enter inductance settings. Use used for stainless steel and spray arc knob to adjust value from min −50% to max applications.

  • Page 36: Welding Process, Material And Gas Type Selection

    5-8. Welding Process, Material And Gas Type Selection Process Soft Key Press key to enter the welding process menu screen. Ampere/WFS Control Knob Turn knob to scroll welding Turn knob to scroll through process welding process, material and gas type. Use soft key to select and or continue settings.

  • Page 37: Unit Settings

    5-9. Unit Settings A. Wire Feed Speed Unit Turn knob to scroll settings Voltage Voltage Press to return Press to to home screen change settings Settings Soft Key follow: press CHANGE soft key to change Turn knob to scroll through unit settings value from meter per minute (m/min) to inch menu.
  • Page 38 B. Remote Control Settings Turn knob to scroll settings Voltage Remote Control Symbol Voltage Press to return Press to to home screen change settings Settings Soft Key proceed as follow: press CHANGE soft key Turn knob to scroll through unit settings to change from OFF (Remote Control dis- menu.
  • Page 39 C. Factory Reset Turn knob to scroll settings Voltage Voltage Press to exit Press to settings confirm settings Settings Soft Key menu screen. Press CHANGE soft key until Turn knob to scroll through unit settings the confirmation message appears on the menu.

  • Page 40: Loading And Saving Welding Programs

    5-10. Loading And Saving Welding Programs Turn knob to scroll weld programs Empty line Arc Length Press to save program Saved program number Arc Length Press to return to home screen with loaded program Press to return to home number screen without loaded program Arc Length...

  • Page 41: Wire Material, Wire Diameter, And Gas Selection Table

    5-11. Wire Material, Wire Diameter, And Gas Selection Table MIG Process Material Gas Type Wire Diameter (mm) Manual MIG − − − Mix 80/20 Carbon Steel Synergic MIG Stainless Steel Mix 98/2 AIMg AISi Carbon Steel Mix 80/20 Stainless Steel Mix 98/2 AIMg Pulsed MIG*...

  • Page 42: Model Name And Software Version

    5-12. Model Name And Software Version Model Name Software Version MigMatic 300iP−V1.00 956172313_20-A OM-287348 Page 36...

  • Page 43: 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 44: Error Code Troubleshooting Description And Table

    6-3. Error Code Troubleshooting Description And Table Display Code Fault Description Overtemperature - IGBT1 Primary Power Circuit Overtemperature - IGBT2 Primary Power Circuit Overtemperature - Secondary Rectifier Overtemperature - Output Inductance Overtemperature - Logic PCB (motor driver) 101/103 Temperature Sensor Failed - IGBT1 Primary Power Circuit Temperature Sensor Failed - IGBT2 Primary Power Circuit 102/104 Temperature Sensor Failed - Secondary Rectifier...

  • Page 45: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 059015051-A Figure 7-1. Circuit Diagram for Migmatic 260i OM-287348 Page 39...
  • Page 46 059015052-A Figure 7-2. Circuit Diagram for Migmatic 300iP OM-287348 Page 40...
  • Page 47 059015053-A Figure 7-3. Circuit Diagram for Migmatic 320i OM-287348 Page 41...
  • Page 48 CIRC. CONN. 14 PIN CIRC. CONN. 14 PIN CIRC. CONN. 14 PIN CIRC. CONN. 14 PIN CIRC. CONN. 14 PIN Figure 7-4. Circuit Diagram for Remote Connections OM-287348 Page 42...

  • Page 49: Section 8 − Parts List

    SECTION 8 − PARTS LIST 956172373_18_A Figure 8-1. Wrapper Assembly, MigMatic 260i Item Dia. Part Mkgs. Description Quantity Figure 8-1. Wrapper Assembly, MigMatic 260i ....231554 Handle, Left .
  • Page 50 119503 Label, Logo Miller 240mm ........
  • Page 51 956172373_18_A Figure 8-2. Wrapper Assembly, MigMatic 300iP Item Dia. Part Mkgs. Description Quantity Figure 8-2. Wrapper Assembly, MigMatic 300iP ....231554 Handle, Left ........... . .
  • Page 52 119503 Label, Logo Miller 240mm ........
  • Page 53 956172373_18_A Figure 8-3. Wrapper Assembly, MigMatic 320i Item Dia. Part Mkgs. Description Quantity Figure 8-3. Wrapper Assembly, MigMatic 320i ....231554 Handle, Left ........... . .
  • Page 54 119503 Label, Logo Miller 240mm ........
  • Page 55 956172373_19_A Figure 8-4. Drive Assembly, Wire (2/4 Roll) Item Dia. Part Mkgs. Description Quantity Figure 8-4. Drive Assembly, Wire (2/4 Roll) ....656039021 Front Housing, 4-R Wire Drive SF54037 .
  • Page 56 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 57 Notes Welding Tip: Securely connect work clamp to a clean area close to the weld joint.
  • Page 58 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 59 Effective January 1, 2020 (Equipment with a serial number preface of NA 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 Positioners and Controllers below, Miller Electric Mfg.
  • Page 60 File a claim for loss or damage during Fax: +31 (0) 186 640 880 shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2020 Miller Electric Mfg. LLC 2020−01...

This manual is also suitable for:

True blue migmatic 300ipTrue blue migmatic 320i059015051059015052059015053

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