Miller Millermatic 350 Owner's Manual
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Miller Millermatic 350 Owner's Manual

Millermatic 350 and millermatic 350p with roughneck 4012 gun
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Millermatic 350 And
Millermatic 350P
with Roughneck 4012 Gun
OM-1327
2005−11
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
R
File: MIG (GMAW)
213 814N

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  • Page 1 OM-1327 213 814N 2005−11 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 350 And Millermatic 350P with Roughneck 4012 Gun Visit our website at File: MIG (GMAW) www.MillerWelds.com...
  • Page 2 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 4 TABLE OF CONTENTS SECTION 5 − PROGRAMMING ..............5-1.

  • 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

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • 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

    D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...

  • 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 Max. Open Amps Input at Rated Output Circuit Circuit Rated Output Rated Output 60 Hz 60 Hz 200 V 230 V 460 V 575V Voltage 300 A at 350 A at 13.1 11.2 Single-Phase 32 VDC, 32 VDC, (1.7*)

  • Page 14: Volt-Ampere Curve

    3-3. Volt-Ampere Curve Normal Volt-Ampere Curves The volt-ampere curves show the M AXVO LTS normal minimum and maximum M INVOLTS voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. AMPERAGE 217 443-A 3-4.

  • Page 15: Installing Work Clamp

    3-5. Installing Work Clamp Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door. Tools Needed: 3/4 in 803 540-B 3-6. Installing Welding Gun/Cable Holder Welding Gun/Cable Holder Wrapper Slots...

  • Page 16: Installing Welding Gun

    3-7. 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 17: Connecting Spoolmatic) 15A Or 30A Gun

    3-8. Connecting Spoolmatic) 15A Or 30A Gun Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Shielding Gas Hose Route weld cable and gas hose through opening in front panel. Positive Weld Output Terminal Connect weld cable to weld output terminal.

  • Page 18: Connecting Xr Edge, Xr-A Gun, Or Xr-A Python

    3-9. Connecting XR Edge, XR-A Gun, Or XR-A Python XR Edge guns prior to serial no. LE079101 require an adapter cord (part no. 195 498). Gun End Gun Liner Wire Outlet Guide Trim excess liner from end of gun so no more than 3/32 in (2.4 mm) of liner extends past wire outlet guide.

  • Page 19: Setting Gun Polarity For Wire Type

    3-10. Setting Gun Polarity For Wire Type Changing Polarity Polarity Changeover Information Always read and follow manufacture’s recommended polarity. Wire Drive Work Clamp Lead Assembly Lead Positive Negative Terminal Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW).

  • Page 20: Installing Gas Supply

    3-11. 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/flowme- ter with CO shielding gas. See Parts List for optional Cylinder Valve gas regulator/flowmeter.

  • Page 21: Electrical Service Guide

    3-13. Electrical Service Guide 60 Hz Single Phase 60 Hz Three Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Circuit Breaker , Time-Delay Normal Operating Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) (31) (26) (70)

  • Page 22: Selecting Input Voltage (200/230/460 Volt Models Only)

    3-14. Selecting Input Voltage (200/230/460 Volt Models Only) Y Turn Off welding power source, disconnect input Be sure to reinstall all four screws power, and check voltage on securing relinking board in place. input capacitors according Section before proceeding. Check input voltage available at site.

  • Page 23: Selecting A Location And Connecting 3-Phase Input Power

    3-15. Selecting A Location And Connecting 3-Phase Input Power Y Do not move or operate unit where it could tip. = GND/PE Earth Ground 18 in (457 mm) for airflow Rear Panel Tools Needed: Ref. 803 543-C / 803 766-A Y Installation must meet all National and Rating Label conductor to disconnect device grounding...

  • Page 24: Selection A Location And Connecting 1-Phase Input Power

    3-16. Selection A Location And Connecting 1-Phase Input Power Y Do not move or operate unit where it could tip. =GND/PE Earth Ground 18 in (457 mm) for airflow Rear Panel Tools Needed: Ref. 803 543-C / 803 766-A Y Installation must meet all National and Three Conductor Power Cord Preparation Disconnect Device Grounding Terminal Local Codes - have only qualified...

  • Page 25: Threading Welding Wire For Roughneck Gun

    3-17. Threading Welding Wire For Roughneck Gun Wire Spool Welding Wire Inlet Wire Guide Drive Roll Intermediate Wire Guide Outlet Wire Guide Pressure Adjustment Knob 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 26: Threading Welding Wire For Xr Edge, Xr-A Gun, Or Xr-A Python

    3-18. Threading Welding Wire For XR Edge, XR-A Gun, Or XR-A Python Wire Spool Welding Wire Inlet Wire Guide Drive Roll Intermediate Wire Guide Outlet Wire Guide Pressure Adjustment Knob Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to IMPORTANT! keep it from unraveling.

  • Page 27: Threading Welding Wire Through Xr Guns

    3-19. Threading Welding Wire Through XR Guns Y Welding wire is electrically live when gun trigger is used to jog wire. For XR-A Edge Gun: Refer to Section 3-18 for instruc- tions on feeding wire through welding power source. Pressure Roll Assembly Lay gun cable out straight.

  • Page 28: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls Ref. 213 935-A Pulse Indicator Light Use button to access Timers, Process and 12 Weld Functions/Setup Indicator Wire menus. Lights Pulse only lights if unit has the VOLTS illuminates in MIG welding mode Arc Control Button indicating volts in left display can be pulse MIG module and is programmed adjusted.

  • Page 29: Jog Mode

    4-3. Jog Mode If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow because gas valve is located inside spool gun.

  • Page 30: Weld Parameters For Mig And Pulse Mode

    4-9. Weld Parameters For MIG And Pulse Mode MIG CHART MIG CHART Note: All chart parameters reference settings for Horizontal T fillet welds. Settings may need to be modified for other types of welding joints or welding positions. 1/2” 3/8” 1/4”...
  • Page 31 Notes OM-1327 Page 27...

  • Page 32: Recommended Crater Fill Parameters

    4-10. Recommended Crater Fill Parameters Recommended Crater Parameters Suggested Suggested Wire Sizes What Process What Material are You Using? (Diameter) are You Welding? Wire Types Shielding Gases 1/2" (12.7mm) OM-1327 Page 28...
  • Page 33 3/8" 1/4" 3/16" 1/8" 19ga. 20ga. (1.05mm) (0.9mm) SC-187 212-A OM-1327 Page 29...

  • Page 34: Section 5 − Programming

    SECTION 5 − PROGRAMMING 5-1. MIG Welding Mode Ref. 213 935-A When the MIG light (2) is illuminated, the Depress SETUP (6) button again to ARC CONTROL unit is in MIG Welding mode. illuminate the WIRE (4) light. This menu is MIG welding mode: Depress...

  • Page 35: Pulse Mig Welding Mode

    5-2. Pulse MIG Welding Mode Ref. 213 935-A When the PULSE MIG (1, 2) is illuminated, OPERATION ARC CONTROL the unit is in Pulse MIG Welding mode. Adjust right knob (9) for proper Wire Feed Pulse MIG (1, 2) welding mode: Depress SETUP speed and adjust left knob (8) to change ARC CONTROL (7) button to enter Arc...

  • Page 36: Timers

    5-3. Timers Ref. 213 935-A To enter the TIMERS (5) menu depress the depressed and before the welding arc will DISP Display ( ) − Allows the Wire Speed SETUP (6) button 4 times or until the be allowed to be active. Range of setting is display to show actual welding amperage TIMERS light (5) is illuminated.

  • Page 37: Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill

    5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill Accessing the Arc Times, Arc Starts, Hot Start (aluminum pulse only), and Crater Fill data will also allow access to Software Version data and Motor Calibration function. The software version data and motor calibration function are for use by factory authorized service personnel only.

  • Page 38: Setting Crater Fill

    5-5. Setting Crater Fill Crater parameters are welding gun independent (i.e. crater fill can be on for a spool gun and off for a MIG gun). When using the same welding gun, MIG and pulse programs are independent of each other; however, crater parameters will be the same for all pulse programs.

  • Page 39: Setting Hot Start (Aluminum Pulse Only) Parameters

    5-6. Setting Hot Start (Aluminum Pulse Only) Parameters The factory default setting for Hot Start is “Auto” on 350P models. The Auto setting has preset parameters. Hot Start can also be set to “On” (manual) for customized settings or made inactive when set to Off. Ref.

  • Page 40: System Reset

    5-7. System Reset Accessing the System Reset function will also allow access to Timer Reset RTMR ORST ) and Option Reset ( ) functions. The timer reset and option reset functions are for use by factory authorized service personnel only. Do not use the timer reset or option reset functions if they appear on the displays.

  • Page 41: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. 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 42: Measuring Input Capacitor Voltage

    6-3. Measuring Input Capacitor Voltage Y Significant DC voltage can remain on capacitors after unit is Off. Always check ca- pacitors as shown to be sure they have discharged before working on unit. Turn Off welding power source and disconnect input power. Remove case.

  • Page 43: Changing Drive Roll And Wire Inlet Guide

    6-4. 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 Intermediate Guide Drive Roll The drive assembly comes equipped with factory installed .035/.045 combination drive Stamped...

  • Page 44: Troubleshooting

    6-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-15 or 3-16). Replace building line fuse or reset circuit breaker if open (see Section 3-15 or 3-16). Secure gun trigger connections (see Section 3-7). Have Factory Authorized Service Agent check Power switch.

  • Page 45: Help Displays

    6-6. Help Displays HELP HELP HELP HELP HELP HELP HELP HELP HELP SAVE HELP 350P HELP JOG MODE HELP OM-1327 Page 41...
  • Page 46 Help 4 Help 9 All directions are in reference to the Indicates gun trigger was pulled and held for Indicates a malfunction in Pulse MIG front of the unit. All circuitry referred to is 2 minutes without a welding arc established function.
  • Page 47 Notes OM-1327 Page 43...

  • Page 48: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For 200V/230V/460V Models OM-1327 Page 44...
  • Page 49 224 242-A OM-1327 Page 45...
  • Page 50 Figure 7-2. Circuit Diagram For 460V/575V Models OM-1327 Page 46...
  • Page 51 223 926-A OM-1327 Page 47...

  • Page 52: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 803 545-C Figure 8-1. Main Assembly OM-1327 Page 48...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... . . 212829 DOOR,ACCESS WIRE COMPARTMENT .......
  • Page 54 Hardware is common and not available unless listed. 803 546-B Figure 8-2. Baffle, Center w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) ... . 058427 RING,RETAINING SPOOL .
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 7) (Continued) ..223542 KIT,MM350 CONTROL BOARD W/ INSTRUCTIONS (200/230/460V model) 1 ..223670 KIT,MM350 CONTROL BOARD W/ INSTRUCTIONS (460/575V model) .
  • Page 56 Hardware is common and not available unless listed. 803 552-A Figure 8-3. Inverter Assy Item Dia. Part Mkgs. Description Quantity Figure 8-3. Inverter Assy (Fig 8-1 Item 9) ..188634 CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/COVER .
  • Page 57 Item Dia. Part Mkgs. Description Quantity Figure 8-3. Inverter Assy (Fig 8-1 Item 9) (Continued) ..221043 CIRCUIT CARD ASSY,INTERCONNECT (200/230/460V model) ....
  • Page 58 Hardware is common and not available unless listed. 803 547-C Figure 8-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 23) ... . . 212837 HANDLE, .
  • Page 59 Hardware is common and not available unless listed. 803 549-B Figure 8-5. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-5. Panel, Rear w/Components (Fig 8-1 Item 10) ... . . 212820 PANEL,REAR .
  • Page 60 See Table 8-1 Hardware is common and not available unless listed. Drive Roll & Wire Guide Kits. 803 548-B Figure 8-6. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 8-6. Wire Drive Assembly 213137 ... . . 223541 .
  • Page 61 Item Dia. Part Mkgs. Description Quantity 213137 Figure 8-6. Wire Drive Assembly (Continued) ... . . 089800 ..NUT, 250−20 .44HEX .22H STL PLD .58D FLANGE DEFOR .
  • Page 62 Item Number Figure 8-7. Consumables Flowchart OM-1327 Page 58...
  • Page 63 Item Part Description Quantity Figure 8-7. Consumables Flowchart Table 8-2. Nozzles ♦176238 ... . NOZZLE, spot flat (requires diffuser 209099, used with any heavy duty FasTipt contact tip) ........♦176240 .
  • Page 64 Item Part Description Quantity Figure 8-7. Consumables Flowchart (Continued) Table 8-5. Tapered FasTipt Contact Tips* ♦209024 ... . .023 in (0.6 mm) ........... . ♦209025 .
  • Page 65 Item Part Description Quantity Figure 8-7. Consumables Flowchart (Continued) Table 8-10. Goosenecks ... +199 625 GOOSENECK, jacketed 4.5 in/50deg wrench swivel (standard on 300 & 400 amp models) ........
  • Page 66 For consumable items 1 thru 7 see Figure 8-7. 802 630-D Figure 8-8. 4012 Gun OM-1327 Page 62...
  • Page 67 ..LABEL, gun handle Miller Roughneck ....... .
  • Page 68 Notes...
  • Page 69 Notes...
  • Page 70 Notes...
  • Page 71 Effective January 1, 2005 (Equipment with a serial number preface of “LF” 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 Induction Heating Coils and Blankets below, Miller Electric Mfg.
  • Page 72 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. 10/05...

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Millermatic 350p

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