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

Miller Millermatic 300 Owner's Manual

Arc welding power source and wire feeder with meters
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www.MillerWelds.com
Millermatic 300
With Meters
OM-1321
197 953M
2005−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
File: MIG (GMAW)

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Summary of Contents for Miller Millermatic 300

  • Page 1 OM-1321 197 953M 2005−09 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 300 With Meters File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • 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 _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use 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: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

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

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Amps Input at Rated Output, 60 Hz; Three-Phase Max. Open Max. Open Rated Output Rated Output Circuit Voltage 200 V 230 V 460 V 575V 300 A at 32 VDC, 240 A at 32 VDC, 23.5 19.0 18.6...

  • Page 14: Volt-Ampere Curve

    3-3. 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. 185 560 3-4. Installing Work Clamp Work Cable Boot Route cable through front panel...

  • Page 15: Installing Welding Gun

    3-5. 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

    3-8. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. See Parts List for optional Cylinder Valve gas regulator/flowmeter.

  • Page 17: Inductance Selection

    3-10. Inductance Selection This unit is factory set for high inductance. High inductance is typically used to soften the arc and flatten the weld bead profile. To change inductance to low, pro- ceed as follows: Tools Needed: Remove lower left side panel. Stabilizer Z 3/8, 7/16 in Lead 24...

  • Page 18: Selecting A Location And Connecting Input Power (Linking For 200/230/460 Volts Model Only)

    3-12. Selecting a Location and Connecting Input Power (Linking For 200/230/460 Volts Model Only) 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 3-11). Install conductors in conduit or equivalent into a deenergized line disconnect device.

  • Page 19: Threading Welding Wire

    3-13. 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 4 − Operation

    SECTION 4 − OPERATION 4-1. 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: Voltmeter And Wire Feed Speed Meter Operation

    4-2. 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: Weld Parameter Chart

    4-3. 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 5 − Maintenance &Troubleshooting

    SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. 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

    5-4. 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

    5-6. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-12). Replace building line fuse or reset circuit breaker if open (see Section 3-12). Reset circuit breaker CB1 (see Section 5-2). Secure gun trigger connections (see Section 3-5).
  • Page 27 Notes OM-1321 Page 23...

  • Page 28: 200/230/460 Models Circuit Diagram

    SECTION 6 − ELECTRICAL DIAGRAM Figure 5-1. Circuit Diagram For 200/230/460 Volts Model OM-1321 Page 24...
  • Page 29 197 482-D OM-1321 Page 25...
  • Page 30 Figure 5-2. Circuit Diagram For 575 Volts Model OM-1321 Page 26...
  • Page 31 207 116-A OM-1321 Page 27...

  • Page 32: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. 802 519 Figure 6-1. Main Assembly OM−1321 Page 28...
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly . . . PLG8 008 072 . . . HOUSING RECEPTACLE & SOCKETS ....... .
  • Page 34 Hardware is common and not available unless listed. Ref. 802 518-A Figure 6-2. Baffle, Center w/Components OM−1321 Page 30...
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) ....058 427 . . . RING, retaining spool ..........
  • Page 36 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Panel, Front w/Components (Fig 6-1 Item 15) ....208 383 LABEL, nameplate ..........
  • Page 37 See Table 6-1 Hardware is common and Drive Roll & Wire Guide Kits. not available unless listed. 802 516-B Figure 6-4. Wire Drive And Gears Item Dia. Part Mkgs. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6-2 Item 27) .
  • Page 38 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 39 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 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER APT & SAF Model Plasma Cutting Torches its original retail purchaser that new Miller equipment sold after...
  • Page 44 1-800-4-A-Miller www.MillerWelds.com Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05...

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