Miller Millermatic 350 Owner'S Manual Download Page 4

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TABLE OF CONTENTS

SECTION 5

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PROGRAMMING

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5-1. MIG Welding Mode

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5-2. Pulse MIG Welding Mode

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5-3. Timers

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5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill

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5-5. Setting Hot Start (Aluminum Pulse Only) Parameters

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5-6. Setting Crater Fill

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5-7. Recommended Crater Fill Parameters

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5-8. System Reset

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5-9. Motor Calibration Function

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5-10. Set Up Push Motor Torque (SUP)

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SECTION 6

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MAINTENANCE &TROUBLESHOOTING

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6-1. Routine Maintenance

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6-2. Overheating

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6-3. Measuring Input Capacitor Voltage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Changing Drive Roll and Wire Inlet Guide

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6-5. Help Displays

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6-6. Troubleshooting

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SECTION 7

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ELECTRICAL DIAGRAM

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SECTION 8

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PARTS LIST

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WARRANTY

Summary of Contents for Millermatic 350

Page 1: ...illermatic 350P Processes Description R Arc Welding Power Source and Wire Feeder OM 1327 213 814AA 2009 10 MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding R File MIG GMAW Visit our website at www MillerWelds com ...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation...

Page 3: ...g Welding Gun Cable Holder 13 3 7 Installing Welding Gun 14 3 8 Connecting Spoolmatic 15A Or 30A Gun 15 3 9 Connecting XR Edge XR A Gun XR A Python Or XR Aluma Pro 16 3 10 Setting Gun Polarity For Wire Type 17 3 11 Installing Gas Supply 18 3 12 Installing Wire Spool and Adjusting Hub Tension 19 3 13 Electrical Service Guide 19 3 14 Selecting Input Voltage 200 230 460 Volt Models Only 20 3 15 Seria...

Page 4: ... 6 Setting Crater Fill 35 5 7 Recommended Crater Fill Parameters 36 5 8 System Reset 38 5 9 Motor Calibration Function 39 5 10 Set Up Push Motor Torque SUP 40 SECTION 6 MAINTENANCE TROUBLESHOOTING 41 6 1 Routine Maintenance 41 6 2 Overheating 41 6 3 Measuring Input Capacitor Voltage 42 6 4 Changing Drive Roll and Wire Inlet Guide 43 6 5 Help Displays 44 6 6 Troubleshooting 46 SECTION 7 ELECTRICAL ...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant volt...

Page 6: ...less they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw f...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing un...

Page 8: ...ther Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866...

Page 9: ...ant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s ...

Page 10: ...ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le con...

Page 11: ...r D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonctionn...

Page 12: ...ement fermés les portes et les panneaux des sources de haute fréquence maintenir les éclateurs à une distan ce correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipem...

Page 13: ...5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov NIO...

Page 14: ...OM 1327 Page 10 ...

Page 15: ...045 in 0 8 1 1 mm 030 045 in 0 8 1 1 mm 035 047 in 0 9 1 2 mm Operating Temperature Range 20C to 40C Storage Temperature Range 30C to 50C 3 2 Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermistors open output stops and cooling fan runs Wait fifteen minutes for unit to c...

Page 16: ...cting to weld output terminals Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against coppe...

Page 17: ...ve Output Terminal Connect cable to terminal and cover connection with boot Close door 803 540 C Tools Needed 3 4 in 3 2 1 3 6 Installing Welding Gun Cable Holder 1 Welding Gun Cable Holder 2 Wrapper 3 Screw Locations Remove screws from side panel Place holder against side panel and align screw holes Secure holder to side panel with the previously removed screws Ref 803 545 D Ref 803 539 C 1 2 3 ...

Page 18: ...1 Drive Assembly 2 Gun Securing Knob 3 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 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door Ref 803 541 C 1 4 3 2 ...

Page 19: ...d collar 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose through opening in front panel 4 Positive Weld Output Terminal Connect weld cable to weld output terminal 5 Regulator Flowmeter Route shielding gas hose through wire drive compartment out opening in rear panel and up to regulator flowmeter Connect gas hose to regulator flowmeter Tools Needed 3 4 5 8 in Î Î 1 2 3 4 2 5 3 ...

Page 20: ...tlet 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 4 Gun Securing Knob 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 Be sure to change drive rolls to the proper size and type 5 Gun Trigger Plug Insert plug into receptacle and tight...

Page 21: ...olarity 1 3 4 11 16 in Ref 803 541 A Changing Polarity D Wire Drive Assembly Lead Work Clamp Lead Positive Terminal Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with gas wires GMAW Negative Terminal Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux core wires FCAW Drive assembly becomes negative D ...

Page 22: ...dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended...

Page 23: ...14 14 Max Recommended Input Conductor Length In Feet Meters 101 31 86 26 229 70 217 66 86 26 114 35 178 54 227 85 Min Grounding Conductor Size In AWG 4 8 8 10 12 10 10 14 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL...

Page 24: ...mage unit and void the warranty 1 Voltage Selection View Window Check voltage selected in unit Changing selection is only neces sary if selected value does not match available input voltage 2 Relinking Board PC6 3 Mounting Screws 4 Receptacle RC23 Connection For 230 VAC Input Power 5 Receptacle RC46 Connection For 460 VAC Input Power Move relinking board as needed and connect plug PLG32 in unit to...

Page 25: ... 460ac input voltage model or 460 575 ac input voltage model See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label 1 Input Power Cord Strain Relief 2 Input Power Cord 3 Disconnect Device switch shown in the OFF position 4 Green Or Green Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors L1 L2 A...

Page 26: ...t Power Cord Strain Relief 2 Input Power Cord 3 Black And White Input Conductors L1 And L2 4 Red Input Conductor 5 Green Or Green Yellow Grounding Conductor 6 Insulation Sleeving 7 Electrical Tape Insulate and isolate red conductor as shown Disconnect Device Input Power Connections 8 Disconnect Device switch shown in the OFF position 9 Disconnect Device Grounding Terminal 10 Disconnect Device Line...

Page 27: ...ing WOOD Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch ...

Page 28: ...from unraveling Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire See Section 3 20 for threading welding wire through XR guns Ref 803 544 B 218 243 A 218 244 A S 0627 A Tighten 1 2 3 4 Use pressure indicator scale to set front drive roll pressure to 1 and rear drive roll pressure to less...

Page 29: ...roll pressure should be set at minimum Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Do not exceed midrange setting Cut off wire Close and latch door Turn welding power source Off Nonconductive Surface For XR A Edge Gun For XR A Pistol Gun 1 Pressure Roll Assembly 2 Drive Roll 3 Thumbscrew Lay gun cable out straight Open top cover and lift pressure arm and open pre...

Page 30: ... ARC LENGTH illuminates in Pulse MIG welding mode indicating Arc Length can be adjusted SETUP illuminates when a parameter on the corresponding display above the light can be adjusted WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted AMPS illuminates indicating welding amps appears in the display instead of wire speed during welding and for 5 seco...

Page 31: ...red unused gun to make it the active gun Once the trigger is pressed the unit will recall stored data and both displays will show the last programmed values for that particular gun If the unit is powered down and back on again the gun last used will become the current active gun 4 6 Pulse MIG Mode Voltage Adjustment In Pulse MIG mode there is no manual voltage adjustment instead voltage is synergi...

Page 32: ... 18 5 160 18 0 115 17 0 90 16 5 80 28 5 485 19 5 330 18 5 275 18 0 260 16 5 200 16 0 155 15 5 135 15 0 100 14 5 95 USE SPRAY 19 0 220 18 0 200 17 5 170 16 2 150 16 0 130 15 5 100 24 0 400 23 0 300 20 5 250 20 0 235 19 5 175 19 0 160 045 045 035 23 0 220 21 5 200 20 5 175 20 0 150 19 0 110 18 5 105 25 0 450 22 5 440 21 5 375 21 0 325 20 0 275 18 0 235 18 5 200 17 5 150 29 3 530 12 7mm 9 5mm 6 4mm 4...

Page 33: ...ainless Steel 035 4043 1 2 12 7mm 500 450 450 650 600 750 3 8 9 5mm 450 350 390 550 550 500 650 1 4 300 200 325 405 720 400 400 550 200 150 260 350 640 300 300 450 150 125 200 290 450 250 200 310 125 100 140 190 310 200 175 210 100 75 110 165 245 150 150 185 75 50 90 115 200 85 100 150 75 150 130 100 Argon Aluminum PULSE C HAR PULSE C HART 6 4mm All chart parameters are based on the following defa...

Page 34: ...unction menus are enabled TIMERS light will stay on to allow for adjust ment of crater parameters and timers see Section 5 6 Depress SETUP 6 button again to exit menus and enter MIG welding mode OPERATION Adjust welding Voltage with left knob 8 and Wire Feed Speed with right knob 9 Refer to MIG welding chart for proper Voltage and Wire Feed Speed setting in reference to material type material thic...

Page 35: ...gth will de fault to 50 if never adjusted previously Re fer to Pulse MIG welding chart for proper Wire Speed setting for metal and metal thickness being welded see Section 4 9 All Pulse MIG programs are setup with the gases listed in the Pulse MIG welding chart If alternate gases are used adjust Arc Length and or Sharp Arc Arc Con trol 7 to adjust arc characteristics ARC LENGTH Arc length can be a...

Page 36: ... of setting is from 0 5 seconds Postflow POST The amount of time that the shielding gas will flow after the arc has been shut off Range of setting is 0 10 seconds Spot Timer SPOT The amount of time that the arc will be active before it shuts off automatically Range of setting is from 0 120 seconds Spot timer is reset upon re lease of welding gun trigger Display DISP Allows the Wire Speed display t...

Page 37: ...right knob 4 until ON appears in the display The Crater Fill display can be turned off after parameters are set in pro grams but remember that once crater fill is turned on in any program it will remain on even though it does not ap pear in the displays because Crater Fill display is turned off To exit this menu press either the SETUP 1 or ARC CONTROL 2 button or press a gun trigger on any welding...

Page 38: ...isplay SPWR Start Power Range for start power is 100 250 as a per cent of wire feed speed SPWR maximum setting will depend on set wire feed speed and may not allow a setting of 250 under certain conditions STMR Start Time Time range is 0 0 0 5 seconds for hot start to be on STRL Start Arc Length Range for start arc length is 0 99 that changes arc length from shorter to longer RMPT Ramp Time Time r...

Page 39: ...r volts range is 10 0 32 0 volts or arc length range is 0 99 see Section 5 7 Rotate left knob 2 to change display to TDLY for time delay This setting is for spot or skip welding without crater fill if the arc time is less than the set time Time range is 0 0 5 0 seconds i e if TDLY is set for 2 0 seconds weld operation will not go into crater if gun trigger is released before 2 0 seconds To exit th...

Page 40: ...lerWelds com OM 1327 Page 36 5 7 Recommended Crater Fill Parameters What Process are You Using What Material are You Welding Suggested Wire Types Suggested Shielding Gases Wire Sizes Diameter Recommended Crater Parameters P U L S E M I G 1 2 12 7mm ...

Page 41: ... A complete Parts List is available at www MillerWelds com OM 1327 Page 37 SC 187 212 A 19ga 20ga 0 9mm 1 05mm 3 8 1 4 3 16 1 8 ...

Page 42: ... OFF will appear on the right display To prepare the unit for system reset rotate right knob until ON appears on the right display To apply the system reset function press SETUP 1 button and wait until unit completely reboots before performing any other operations Ref 213 935 A 1 Accessing the System Reset function will also allow access to Timer Reset RTMR and Option Reset ORST functions The time...

Page 43: ...play 6 Arc Control Button Open drive rolls in welding power source and in push pull gun if one is attached to unit Simultaneously press Setup and Arc Control buttons Rotate left knob until MCAL is displayed Rotate right knob until YES is displayed Press and hold gun trigger Wire drive speed will be overridden to 50 IPM for 12 seconds and then to 800 IPM for 12 seconds When CAL DONE appears on the ...

Page 44: ...em and rotate the right knob to change the setting The following items can be adjusted by rotating the left knob counterclockwise CCW Set up Push Motor Torque SUP This feature is only active when a push pull gun is connected to the welding power source The SUP setting will adjust the over torque limit of the push motor inside the welding power source The range is 0 250 and the default value is 130...

Page 45: ...horized Service Agent Reference Every 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals n Check Gun Cable Every 6 Months OR Inside Unit Clean Drive Rolls 6 2 Overheating Thermistors RT1 and RT2 protect the unit from damage due to overheating If output diode heatsink or IGBT heatsink gets too hot RT1 and or RT2 opens and output stops The...

Page 46: ...d before working on unit Turn Off welding power source and disconnect input power Remove case 1 Input Capacitor C3 Terminals 2 Input Capacitor C4 Terminals 3 Voltmeter Check input capacitors as shown Measure the dc voltage across the positive and negative terminals until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall case when finished Tools Needed 5 16 in 3 6 3 Measurin...

Page 47: ...ls are installed cor rectly Combination drive rolls consist of two different sized grooves The stamped markings on the end sur face of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the carrier gear is the groove for the wire size viewed on the end surface of the drive roll Install correct drive roll for wire size and type U Grooved drive rolls are...

Page 48: ...ds com OM 1327 Page 44 6 5 Help Displays A V A V A V HELP 0 A V A V A V A V A V A V A V HELP 1 HELP 2 HELP 3 HELP 4 A V HELP 5 A V HELP 6 HELP 8 HELP 9 HELP 10 TIP SAVE MM 350P A V MM 350 A V JOG A V HELP 7 A V HELP 11 Displays a jog wire feed speed XXX ...

Page 49: ...ire guides or contact tip S Help 6 Indicates a malfunction in wire feed system and or external drive motor overcurrent con dition spool gun or push pull gun Check for proper spool brake adjustment or obstructions in wire feed system Clean or replace liner wire guides or contact tip S Help 7 Indicates input voltage malfunction voltage too high or too low causing unit to automatically shut down Turn...

Page 50: ...t voltage or check for low line voltage see Section 3 16 or 3 17 Have Factory Authorized Service Agent check main control board and user interface board Low high or erratic wire speed Readjust front panel settings see Section 4 1 Change to correct size drive rolls see Section 6 4 Readjust drive roll pressure see Section 3 18 Replace inlet guide contact tip and or liner if necessary see gun Owner s...

Page 51: ...OM 1327 Page 47 Notes ...

Page 52: ...OM 1327 Page 48 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram For Welding Power Source ...

Page 53: ...OM 1327 Page 49 246 030 A ...

Page 54: ...45 in 052 in 062 in 035 in 045 in 052 in 062 in 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm Kit No 087 132 046 780 046 781 046 782 046 783 046 784 044 750 046 785 046 786 046 787 046 792 046 793 046 794 046 795 Drive Roll Part No Type 087 130 053 695 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 132 958 132 957 132 956 132 955...

Page 55: ...s and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays work station table tops ...

Page 56: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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