Miller Millermatic 300 Owner's Manual
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Miller Millermatic 300 Owner's Manual

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Millermatic 300
With Meters
OM-1321
197 953
October 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R

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Summary of Contents for Miller Millermatic 300

  • Page 1 OM-1321 197 953 October 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 300 With Meters Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Amps Input at Rated Output, 60 Hz; Three-Phase Max. Open Max. Open Rated Output Circuit Voltage 200 V 230 V 460 V 300 A at 32 VDC, 240 A at 32 VDC, 23.5 18.6 60% Duty Cycle 100% Duty Cycle (1.7*)

  • Page 14: Volt-Ampere Curve

    2-3. Volt-Ampere Curve Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the welding power source. Curves of other settings fall be- tween the curves shown. ST-185 560 2-4. Installing Work Clamp Work Cable Boot Slide boot onto work cable.

  • Page 15: Installing Welding Gun (Welding Gun Not Included)

    2-5. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar.

  • Page 16: Installing Gas Supply

    2-8. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Regulator/Flow Gauge Install so face is vertical. Gas Hose Connection Fitting has 5/8-18 right-hand threads. Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour).

  • Page 17: Inductance Selection

    2-10. Inductance Selection Remove left side panel. Stabilizer Z Tapped stabilizer Z is factory con- nected to the stabilizer tap which suits most GMAW applications. Tools Needed: Stabilizer Z controls the inductance applied to the weld current. To in- crease inductance and wet out the 3/8, 7/16 in weld puddle, connect to stabilizer Z ending.

  • Page 18: Selecting A Location And Connecting Input Power

    2-12. Selecting a Location and Connecting Input Power Tools Needed: 3/8 in 3/8 in GND/PE 18 in (457 mm) for airflow GND/PE Connect First Size and ratings must comply with applicable codes (see Section 2-11). Install conductors in conduit or equivalent into a deenergized line disconnect device.

  • Page 19: Threading Welding Wire

    2-13. Threading Welding Wire 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. 6 in (150 mm) Open pressure assembly.

  • Page 20: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Voltage Control Turn control clockwise to increase voltage. Wire Speed Control Turn control clockwise to increase wire feed speed. Power Switch Voltmeter Wire Feed Speed Meter 197 812 OM-1321 Page 16...
  • Page 21 3-2. Voltmeter And Wire Feed Speed Meter Operation Voltmeter Wire Feed Speed Meter Power Up Status Both meters display zeros at unit power up. After one second, preset values appear on both meters. The MIG gun settings (not spool gun) are always the default at initial power up of the unit.
  • Page 22 3-3. Weld Parameter Chart SelectingWire, Gasand ControlSettings What Material Suggested Suggested Wire Sizes Wire Types Shielding Gases (Diameter) are You Welding? and Flow Rate Steel Solid (or hard) 100% CO , 20 cfh .023” (0.6 mm) ER70S-6 .030” (0.8 mm) .035”...
  • Page 23 To read setting: Number on left Select Voltage and Wire Speed Based of slash is voltage, number on on Thickness of Metal Being Welded right of slash is wire-speed. “_” Means not recommended. Example: 19.2/398 = VOL TAGE WIRE SPEED 22 ga.

  • Page 24: Section 4 - Maintenance &Troubleshooting

    SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals Check gun cable. 6 Months Blow out or vacuum inside.

  • Page 25: Changing Drive Roll And Wire Inlet Guide

    4-4. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. .045 Groove .035 Groove Anti-Wear Guide Install guide as shown. Intermediate Guide Drive Roll The drive assembly comes Stamped...

  • Page 26: Troubleshooting

    4-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-12). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-5).

  • Page 27: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM 197 482-A Figure 5-1. Circuit Diagram OM-1321 Page 23...

  • Page 28: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. 802 519 Figure 6-1. Main Assembly OM–1321 Page 24...
  • Page 29 . . . LABEL, Miller Millermatic ..........
  • Page 30 Hardware is common and not available unless listed. 802 518 Figure 6-2. Baffle, Center w/Components OM–1321 Page 26...
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) ....058 427 . . . RING, retaining spool ..........
  • Page 32 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Panel, Front w/Components (Fig 6-1 Item ....+196 798 PANEL, front control ..........
  • Page 33 See Table 6-1 Drive Roll & Wire Guide Kits. Hardware is common and not available unless listed. 36 35 20 26 Figure 6-4. Wire Drive And Gears 802 516 Item Dia. Part Mkgs. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 27) .
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 6-4. Wire Drive And Gears (Continued) (Fig 6-2 Item 27) ....602 154 . . . SCREW, 250-20 x .50 hexwhd .50d .
  • Page 35 Table 6-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. V-Knurled rolls for hard shelled cored wires. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
  • Page 39 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 40: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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