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Miller Electric Metro 300DX Owner's Manual

Cc/dc welding generator for smaw and gtaw welding
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Miller
August
1995
Effective With
Form:
Serial No.
OM-1
56 368B
KF941 356
OWNERS
MANUAL
~_' _I_
CE
Metro 300DX
CC/DC
Welding
Generator For SMAW And GTAW
Welding
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Auxiiiary
Power
Rating
Engine
Fuel
Capacity
Sound
Power
iP
Rating
280
A,
31
VDC,
35%
Duty Cycle
250
A,
30 V
DC,
60%
Duty Cycle
225
A,
29 V
DC,
100%
Duty Cycle
20280
72 AMS
(65 Average)
Single-Phasel
3-Phase,
7/10
kVA/kW,
32/15
A.
220/380 V
AC,
50Hz
Ruggenni
RD211
Air-Cooled,
Two-Cylinder,
20
HP Diesel
Engine
11.8 US
gal
(44.6 L)
98 Lwa
23
cover_om
4/95
-
Ref.
ST-158 934-B
'
1995
MILLER Electric
Mfg.
Co.
PRINTED
IN
USA

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Summary of Contents for Miller Electric Metro 300DX

  • Page 1 Duty Cycle (65 Average) 29 V 100% Duty Cycle ST-158 934-B 4/95 Ref. cover_om 1995 August Effective With OWNERS MANUAL Metro 300DX Generator For SMAW And GTAW Auxiiiary Engine Power Rating Single-Phasel 3-Phase, Ruggenni RD211 Air-Cooled, 7/10 kVA/kW, 32/15 Two-Cylinder,...
  • Page 2 This Limited but may and other rights available, Miller Electric Mfg. CALL: FAX: {TE~T] 800-637-2348 (in USA), 414-735-4136 (outside USA) WRITE: Miller Electric Mfg. P.0. Box 1079...
  • Page 3 EI~RATA SHEET After this manual printed, refinements in later in this manual. appearing CHANGES TO SECTION ELECTRICAL DIAGRAM Replace Figure 6-1. Circuit Diagram CHANGES TO SECTION 8 PARTS LIST Change Parts List follows: Dia. Part Mkgs. Added 31-54 176 625 176 626 31-72 **First...
  • Page 4 lxxx XQ0$E0 TO TEF~1IJAL 87>A)~ 2ZIV 85>B>-~ 3o>c>.~L 3tJ>C>~ L~~> >J~ ~-~2>~ I~i~&~ ~ >~ 85>B>~- >~ 3O>C>-~ >~ ~6 >~ L~~> >~ >~. ~-~8>~ >~- ~JLLll:~1 >~- -~ ~- -~-~Q >- TO LOWER FELD 0.~NT TO RA~ FEW 0~ENT ~OVE LEAD 31 TO iT-A ~GVE LEAD 3~ TO...
  • Page 5 RC7/I&G7 >- >2 >- >3> SD-178 OM-156 368B Page...
  • Page 7 Declaration of Miller Electric Manufacturers Name: 1635 W. Manufacturers Address: Appleton, Ni ET R Declares that the product: Directives and Standards: conforms following Machinery Directives: Noise level of Safety Requirements Electrical Machines Rotating Part 5: Classification of Rotating Electrical Machines Insulation coordination for Part 1.:...

  • Page 8: Table Of Contents

    TABLE OF SECTION 1 SAFETY PRECAUTIONS FOR ARC WELDING 1-1. Symbol Usage 1-2. Welding Hazards Engine Hazards 1-3. 1-4. Additional Installation, Operation, 1-5. Principal Safety Standards EMF Information 1-6. SECTION 2 INSTALLATION Generator 2-1. Installing Welding Dimensions, 2-2. Weights, 2-3. Fuel Consumption 2-4.

  • Page 9: Safety Precautions For Arc Welding

    SECTION SAFETY PRECAUTIONS FOR ARC WELDING 1-1. Symbol Usage Means Watch Out! There Warning! procedure! possible hazards ~1!~~d~ This group of PARTS, actions 1-2. Hazards Welding WARNING symbols shown below used When you symbol, watch Information given below Is only Standards listed in Section 1-5.
  • Page 10 CYLINDERS explode contain gas under Shielding cylinders pressure. If damaged, cylinder Since gas cylinders normally part process, be to treat them sure Protect compressed cylinders from mechanical flames, shocks, slag, sparks, open Install cylinders upright position by securing cylinder rack falling support prevent...

  • Page 11: Emf Information

    1-4. Additional Installation, WARNING MOVING PARTS can cause Before working generator, injectors keep engine starting. Block flywheel that it will not turn while generator components. FLYING PIECES OF METAL Injure eyes. Wear safety glasses with side shields shield. STATIC ELECTRICITY circuit boards.

  • Page 12: Installing Welding Generator

    SECTION 2-INSTALLATION 2-1. Installing Welding Generator 2-2. Dimensions, Weights;And Operating Angles Holes Sr-158 OM-1 56 368 Page Dimensions 41 in Height (1041 mm) Width 30 in (762 mm) 54-1/2 in Depth (1384 mm) 29 in (737 mm) 36-3/4 in (933 mm) 9/l6in(l4mm)Dia.

  • Page 13: Rating Label

    2-3. Fuel Consumption 4.73 1,04 0.84 3.78 2.84 1.89 0.42 0.95 0.21 0.00 0.00 2-4. Label Rating 35OHz 50 Hz 50 Hz 1.25 IILII 1.00 ,~,, 7tt+- 0.75 0.50 ~OLEJ I I I I II I 0.00 20] 225 2~Q 275 30) DC WELD AWERES AT 630% DUTY CYCLE POWER...

  • Page 14: Connecting Battery And 2-6. Engine Prestart Checks

    Muffler 2-5. Connecting Battery Installing Pipe 56 368 Page OM-1...

  • Page 15: Weld Output Terminals And

    2-6. Prestart Checks Engine 2-7. Weld Output Terminals And based Weld cable size (AWG) either Selecting Cable Sizes Total Cable (Copper) Length 200ft 150ft 100 ft (30 m) Or Less (45 m) (60 m) 1060% 100% Duty Duty Cycle Cycle drop density least 300 circular mils per ampere.

  • Page 16: Section 3Operating

    2-8. Remote 14 Receptacle REMOTE ST-Isa 934-B *The remaining used. sockets SECTION 3-OPERATING Symbols And Definitions 3-1. OM-156 Page RC1 Information Sockete 24 volts with Contact closure circuit. Circuit common +10 volts dc output Remote control circuit +10 volts dc socket D.

  • Page 17: Front Panel Controls

    3-2. Front Panel Controls idle Lock Switch Using 2100 rpm (No Load) 3200 3200 rpm first 50 hours A Heavy loading during will damage engine. Keep load less 225A 7 kVA than (weld) (power) for first 50 hours. Control Switch Si Engine Use switch operate glow...
  • Page 18 Duty Cycle Overheating 3-3. 4~fl 2cXJ Duty Cycle At 280 Amperes 3-1/2 Minutes 6-1/2 Minutes Welding 3-4. Remote Amperage Control r!1~ ...~ Set Switches OM-156 368 Page DUTY CYCLE Duty Cycle Resting 6 Minutes Welding At 225 100% Duty Cycle Amperes Continuous Welding...

  • Page 19: Section 4Operating

    SECTION OPERATING AUXILIARY EQUIPMENT 4-1. Auxiliary Power Receptacles 35OHz 380V power available (IJ~ Auxiliary recep tacles decreases weld amperage creases. 380 V 15 A Receptacle 220 V 16 A Receptacle 220 V 16 A AC Receptacle supplies 50 Hz three-phase power weld/power speed.

  • Page 20: Maintenance & Troubleshooting

    SECTION 5- MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Repair Cracked Cabies OM-156 368 Page A Stop engine OJ~ See also Recycle engine fluids. 8 Hours 50 Hours fi 100 Hours Clean And Tighten Battery Connections. See Section 200 Hours 300 Hours fi...
  • Page 21 UI VU C., CD std. std. E N G I N E D I E S E L R D 2 1 1 R U G G E R I N I std. std. std. std. cn0) C.) 0) 0) -u...
  • Page 22 5-2. Changing Engine Oil And Oil Filter Tools Needed: ~IIIIIII~ OM-156 Page Stop engine. engine manual for oiVfilter change procedure. Oil Fill Caps (Use Either Oil Drain Valve Close oil drain valve and cap before adding oIl and ning engine. Oil Filter Dipstick Ret.

  • Page 23: Maintenance Label

    5-3. Changing Fuel Filters Cleaner 5-4. Servicing Blow inspect Stop engine. Do not engine without air with cleaner dirty element. only high pulsation-type filter listed replacement maintenance label engine damage occur. Dust Element Housing Dust Valve To Clean air filter: Wipe off cap and housing.

  • Page 24: Adjusting Engine Speed

    5-5. Adjusting Engine Speed Tools Needed: OM-156 368 Page After tuning engine, check engine speeds with tachometer (see table for load speeds). neces adjust speeds follows: saw, Start engine until warm. Turn engine control switch Run/ Idle position. Idle Speed Screw Loosen Turn...

  • Page 25: Overload Protection

    5-6. Overload Protection Tools Needed: 318,1/2in fl~ If fuse breaker continues contact Factory Autho open, rized Seivice Agent. Fuses FuseF2 protects battery excitation circuit. Fuse F3 excitation protects generator circuit. Replace any open fuses. Reinstall before panel operating unit. Circuit Breakers Circuit Breaker CB5 .protects 24 volt...

  • Page 26: Inspecting And 5-9. Troubleshooting

    Cleaning Optional Spark 5-7. Inspecting Tools Needed: 3/8in 5-8. Troubleshooting Welding Trouble No weld Check fuses F2 and output. Have Check Place Remote Have Check fuses F2 and Low weld output. Check Tune Place Remote Have fier weld Check and High output.
  • Page 27 Clean sure Have SR3, Place Remote at Remote 14 Reset circuit breaker CB5 Power Reset power Reset circuit breakers Check Check fuses F2 and Disconnect Have Check fuses F2 and receptacles. Check and Tune-up engine according Have receptacles. Check and receptacles.
  • Page 28 Trouble Or Low Check and High Engine Speed. Engine does not return to idle speed. Have control module. Engine idles but does reach weld Reset circuit breaker CB7 speed. Have control module. Engine run-in Dry engine according during period; uses wetstacking occurs.
  • Page 29 NOTES OM-156 368 Page...

  • Page 30: Electrical Diagram

    SECTION 360V1 220V x~cuxco TO ~B TERMNAL r~n~ 1~~5 87>A) 2X8V 85>8>~ I 85>8>~- 32>c>~- >2 L~i> >~ L!.~>t 1~5~ ~2>~ 87>A>~ 2!.~3 65>O~4~ xi>c>~ ~5>~ ~8>~ >~ L_~> >~ Q~7>QT ~8>~ ~~9>2 4~ >~- ~ ~- -~Q>- TO LOWER FELD 0~NT TO RASE FEW C~~NT ICVE LEAD TI-A...
  • Page 31 RcrnLcl >; >2 >3 rc7/P~.r7 >4 >6 >7 Icl~ LAA__t~~_A__t.. C~PACfl~ 96AJ~) ~2~G22~I SD.172 300-0 OM-156 Page...
  • Page 32 LIST SECTION PARTS *Included w/engine 7-1. Main Assembly Figure OM-156 368 Page...
  • Page 33 -J C.) - J O ) 0) CD 0) 01 0)0) 0) -J UI0) C.)0) CD 1%) 01...
  • Page 34 Item Dia. Part Mkgs. Figure +163828 PANEL, 164507 PANEL, 171 053 SPRING, +163958 COVER, generator 176 104 LABEL, 165 839 HINGE, 167 340 COVER, 107816 HOSE, GAS, ...7 172 295 172 297 BRACKET, BALL GAS 172 296 ...8...3T.. 172 661 BLOCK, 173 734 LINK,...
  • Page 35 Item Dia. Part Mkgs. Figure 167313 LATCH, 166 722 BAFFLE, CR2,3. 090 104 RELAY, ...43.. 173 366 PANEL, mtg components ...45...4T.. BLOCK, .043138 COLD 46... CB9.. 147658 CIRCUIT 164938 ...GLOWPLUG,12V65A CONTACTOR, 155309 47... CB8.. 115427 CIRCUIT CIRCUIT 48.. CB6,7. 083 432 175897 LEVER, 170438...
  • Page 36 Dia. Part Item Mkgs. Figure 162515 RECTIFIER, C1,3 048420 CAPACITOR, C2,4 CAPACITOR, 106641 D1-3 037957 DIODE,rect275A300VRP SCR1,2 162516 THYRISTOR, 028 388 CLAMP, 162442 PANEL, 163608 STABILIZER PANEL, ...89 Fig7-3 164126 TRIM, 167658 PANEL, CIRCUIT 92... PC5.. 148608 141 690 GROMMET, UPRIGHT, 162447 172804...
  • Page 37 Item Part Figure 166770 STUD, 160943 ENDBELL 166727 ROTOR, generator 053390 BEARING, 160566 FAN, +172462 STATOR, generator 172656 GUARD, generator 172674 SPRING, 165850 ADAPTER, ...10 176106 LABEL, 170861 STUD, 125548 HOLDER, 005614 HOLDER, *126984 BRUSH w/SPRING 161306 CAP, 047879 BAR, +When originally displaying ordering...
  • Page 38 Item Part Dia. Mkgs. 072623 R4,5 172070 169299 S6-8 011609 RC2,3 176355 ,043254 RC4,5 087640 141267 175915 CB1-3,10 139 266 GFCI1 172072 156830 154022 147554 083432 170391 021385.. 129525 082788 *048 155 082789 ...22 118066 ...23 119014 097922 ...24 ...25 097924 ...26 072590...
  • Page 39 Item Dia. Part Mkgs. 135 184 038 889 010915 601 836 156 583 035 704 083 147 ...5 010494 ...7 026947 8...CR5,6... 9...CR1,4... 173 069 ...io 171 345 166719 098376 *073426 *142751 087111 ...16 087110 038772 601 219 *Recommended Parts. Spare BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

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