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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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

1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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DEFINITIONS

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2-1. Additional Safety Symbols And Definitions

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2-2. Miscellaneous Symbols And Definitions

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SECTION 3

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SPECIFICATIONS

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3-1. Serial Number And Rating Label Location

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3-2. Specifications

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3-3. Duty Cycle And Overheating

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3-4. Volt-Ampere Curves

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

3-5. Environmental Specifications

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SECTION 4

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INSTALLATION

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

4-1. Installing Gas Supply

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

4-2. Installing Wire Spool And Adjusting Hub Tension

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

4-3. Positioning Jumper Links (230/400V 3-Phase Models)

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4-4. Electrical Service Guide

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4-5. Connecting 3-Phase Input Power

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

4-6. Changing Drive Rolls And Wire Inlet Guide (MigMatic 380 Models)

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4-7. Aligning Drive Rolls and Wire Guide

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4-8. Threading Welding Wire And Adjusting Pressure Roll Tension

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

SECTION 5

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OPERATION

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5-1. Controls For MigMatic 300

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

5-2. Controls For MigMatic 380

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

5-3. Selecting Parameters (MigMatic 300 And 380 Models)

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5-4. Sequencer Controls Settings (MigMatic 300 And 380 Models)

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5-5. Trigger Mode And Spot Time Selection (MigMatic 300 And 380 Models)

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5-6. Welding Wire Loading Settings (MigMatic 300 And 380 Models)

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5-7. Resetting Unit To Factory Default Settings (MigMatic 300 And 380 Models)

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5-8. Controls For MigMatic 300DX

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5-9. Controls For MigMatic 380DX

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

5-10. Burnback And Run-In Controls (DX Models Only)

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5-11. Welding Power Source Input Line Voltage Adjustment (DX Models Only)

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5-12. Welding Power Source Setup Menu (DX Models Only)

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5-13. Trigger Mode Selection (DX Models Only)

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5-14. Welding Wire Diameter Selection For Synergic MIG (DX Models Only)

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5-15. Welding Wire Type Selection For Synergic MIG (DX Models Only)

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5-16. Gas Selection For Synergic MIG (DX Models Only)

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5-17. Selecting Manual MIG Welding (DX Models Only)

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5-18. Selecting Synergic MIG Welding (DX Models Only)

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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. Welding Gun And Wire Drive Assembly

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6-3. Unit Overload

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6-4. Troubleshooting

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SECTION 7

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ELECTRICAL DIAGRAMS

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SECTION 8

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PARTS LIST

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WARRANTY

Содержание MigMatic 300

Страница 1: ...tion MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source Wire Feeder OM 251958F 2018 02 MigMatic 300 380 And DX R CE File MIG GMAW For product information Owner s Manual translations and...

Страница 2: ...ucts 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 quick and easy With Miller you...

Страница 3: ...5 1 Controls For MigMatic 300 22 5 2 Controls For MigMatic 380 23 5 3 Selecting Parameters MigMatic 300 And 380 Models 24 5 4 Sequencer Controls Settings MigMatic 300 And 380 Models 25 5 5 Trigger Mod...

Страница 4: ...2 MIGMATIC 380 DX 400VAC 029015543 MIGMATIC 380 230 400VAC 029015547 MIGMATIC 380 DX 230 400VAC 029015548 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU...

Страница 5: ...options welding programs are changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distance...

Страница 6: ...options welding programs are changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distance...

Страница 7: ...electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneelin...

Страница 8: ...ot possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that weldi...

Страница 9: ...o move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guideline...

Страница 10: ...eorge Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standard...

Страница 11: ...ycling office or your local distributor for further information Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Protect...

Страница 12: ...objects away Safe33 2017 04 Consult rating label for input power requirements See rating label on unit and check input voltage available at site Safe34 2012 05 Become trained and read the instruction...

Страница 13: ...rnating Current AC Direct Current DC Remote On Off Protective Earth Ground Line Connection Three Phase Single Phase Gas Metal Arc Welding GMAW U1 Primary Voltage I1max Rated Maximum Supply Current I1e...

Страница 14: ...AC 50 60 Hz 180 A 23 V 230 A 25 5 V 300 A 29 0 V 43 5 30 300 A 471 x 825 x 1066 88 Net Wire feed speed range 1 3 mpm to 26 mpm Model Rated Output Max Open Circuit Voltage Amperage Range DC Dimension m...

Страница 15: ...ll between the curves shown MigMatic 300 0 5 0 1 5 1 0 2 5 2 0 3 5 3 0 4 5 4 0 5 0 4 3 0 2 3 0 0 3 0 8 2 0 6 2 0 4 2 0 2 2 0 0 2 0 8 1 0 6 1 0 4 1 0 2 1 0 0 1 0 8 0 6 0 4 0 2 0 DC Amperes DC Volts Max...

Страница 16: ...lectrical power is provided by the public low voltage supply system There can be potential difficulties in ensuring electromagnetic compatibility in those locations due to con ducted as well as radiat...

Страница 17: ...lightly Gas flow blows 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 Conne...

Страница 18: ...OM 251958 Page 12 4 2 Installing Wire Spool And Adjusting Hub Tension Ref D2 Tools Needed Hub Assembly 15 Kg Wire Spool Assembly 5 Kg Wire Spool Assembly 1 Spacers Use only for 5Kg spool 1...

Страница 19: ...connecting input conductors from unit Follow established procedures regarding the installation and removal of lockout tagout devices Check input voltage available at site 1 Jumper Link Label Check lab...

Страница 20: ...20 5 40 23 Maximum Effective Supply Current I1eff A 21 1 12 1 23 7 13 6 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 Normal Operating Fuses3 40 25 50 25 50 30 60 30 Min Input Con...

Страница 21: ...OM 251958 Page 15 Notes...

Страница 22: ...OM 251958 Page 16 4 5 Connecting 3 Phase Input Power input2 2012 05 Ref 803766 C Ref 956142845_5_14_A GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed...

Страница 23: ...connect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Co...

Страница 24: ...ssible without touching Tighten screw 3 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite...

Страница 25: ...as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opp...

Страница 26: ...open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Close pressure roll a...

Страница 27: ...ly 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 trigge...

Страница 28: ...dicator Light PL1 White LED PL1 is lit when power is On 6 Wire Feed Speed Control R1 Turn control clockwise to increase wire feed speed This control will also allow adjustment of sequencer parameters...

Страница 29: ...power is On 6 Wire Feed Speed Control R1 Turn control clockwise to increase wire feed speed This control will also allow adjustment of sequencer parameters see Section 5 4 7 Digital Display Meter Disp...

Страница 30: ...tup Button P1 To select welding parameters pro ceed as follows Press and release P1 push button to select desired parameter V A or and the corresponding LED will light up Display meter D1 displays sel...

Страница 31: ...value Default 100 min 25 max 100 Run In control is active only with the slope time set to 0 sec 9 Slope Time Control LED Use control to select amount of time that it takes to slope up down from initia...

Страница 32: ...ode When trigger is pressed welding starts When trigger is released welding stops 4 4 t Trigger Mode When trigger is pressed welding starts When trigger is released welding continues When trigger is p...

Страница 33: ...ess and hold for three seconds the torch trigger to load welding wire After pressing and holding the torch trigger gas valve and in put power contactor are dis abled This method prevents the risks of...

Страница 34: ...ngs MigMatic 300 And 380 Models This procedure will delete all oper ator specified parameters and re call all factory parameters 1 Trigger Mode Selector Switch P2 Press and hold P2 button and factory...

Страница 35: ...ire Feed Speed WFS Trim Arc Length And Line Input Adjustment Control R1 See Section 5 11 7 Digital Display Meter Displays values and parameters for selected welding processes 8 Setup Button Use button...

Страница 36: ...gital Display Meter Displays values and parameters for selected welding processes 8 Setup Button Use button to select parameters V A and the sequencer control 9 Trigger Mode Button Use control to sele...

Страница 37: ...odels Only 1 Burnback Control R3 Use control to set time welding wire stays energized after trigger is re leased 2 Wire Run In Speed Control R2 Use control to determine rate at which welding wire feed...

Страница 38: ...value 8 Positive Percentage Input Line Voltage Adjustment Display Indicator A dash in the right segment of the meter and a flashing PL1 indicates the need for a positive correction Turn R1 clockwise...

Страница 39: ...And line Input Ad justment Control to change wire feed speed or amperage depend ing upon which parameter is active Rotate voltage control to change voltage when voltage LED is lit The value of the se...

Страница 40: ...tin ues When trigger is pressed and released a second time welding stops 3 Trigger Mode Selection Button Press button to select desired trigger mode and lite corresponding LED 2 t and 4 t trigger meth...

Страница 41: ...n to select desired wire type Fe ferris CrNi stainless steel Al aluminum or CuSi Cop per Silicon and lite corresponding LED 1 2 5 16 Gas Selection For Synergic MIG DX Models Only 1 ShieldingGas Types...

Страница 42: ...y Meter In Manual MIG mode the operator may need to adjust main welding parameters for specific arc characteristics Use setup button to select desired parameter voltage amperage or preset wire feed sp...

Страница 43: ...et er is displayed on the meter Turn voltage control S2 clockwise to increase voltage Turn wire feed speed control R1 clockwise to increase wir3e feed speed 6 Trigger Mode Button Use button to select...

Страница 44: ...light coat of oil or grease to drive motor shaft OR 6 2 Welding Gun And Wire Drive Assembly 1 Welding Gun Check gun liner for blockage or kinks 2 Wire Drive Assembly Check for jammed wire binding dri...

Страница 45: ...ck main transformer T1 for signs of winding failure Check continuity across windings and check connections Check secondary voltages Replace T1 if necessary Have Factory Authorized Service Agent check...

Страница 46: ...OM 251958 Page 40 SECTION 7 ELECTRICAL DIAGRAMS 956142850 B Figure 7 1 Circuit Diagram for Migmatic 300 230 400 VAC...

Страница 47: ...OM 251958 Page 41 956142846 B Figure 7 2 Circuit Diagram for Migmatic 300 400 VAC...

Страница 48: ...OM 251958 Page 42 956142852 B Figure 7 3 Circuit Diagram for Migmatic 380 230 400 VAC...

Страница 49: ...OM 251958 Page 43 956142848 B Figure 7 4 Circuit Diagram for Migmatic 380 400 VAC...

Страница 50: ...OM 251958 Page 44 956142851 C Figure 7 5 Circuit Diagram for Migmatic 300 DX 230 400 VAC...

Страница 51: ...OM 251958 Page 45 956142847 C Figure 7 6 Circuit Diagram for Migmatic 300 DX 400 VAC...

Страница 52: ...OM 251958 Page 46 956142853 C Figure 7 7 Circuit Diagram for Migmatic 380 DX 230 400 VAC...

Страница 53: ...OM 251958 Page 47 956142849 C Figure 7 8 Circuit Diagram for Migmatic 380 DX 400 VAC...

Страница 54: ...0 V 400 1 6 956142862 Rating Plate MigMatic 300 V 230 400 1 6 956142858 Rating Plate MigMatic 380 V 400 1 6 956142860 Rating Plate MigMatic 380 V 230 400 1 7 000207291 Label Primary Power Connections...

Страница 55: ...56029242 Nameplate Front Lower MigMatic 300 300DX 1 19 356029243 Nameplate Front Lower MigMatic 380 380DX 1 20 056067267 Switch Power 1 1 21 356029235 Nameplate Front Upper MigMatic 300 1 21 356029237...

Страница 56: ...el Reel w Ring 1 1 7 156015027 Spool Nut Plastic 1 1 8 156023170 Spacer Spool Holder D 50 H 18 1 1 9 156023171 Spacer Spool Holder D 50 H 30 1 1 10 F1 056092097 Fuse 2A 250V 5 x 20 T 1 1 11 356029240...

Страница 57: ...1 36 Z 057098023 Choke MigMatic 380 D 8 50 L 305 37 CB1 056067283 Circuit Breaker 5A 1 1 38 056092098 Holder Fuse 1 1 39 PC2 057084167 Circuit Board F O D 1 1 40 FM1 057035021 Fan 230VAC 1 1 41 GSV 05...

Страница 58: ...el Reel w Ring 1 1 7 156015027 Spool Nut Plastic 1 1 8 156023170 Spacer Spool Holder D 50 H 18 1 1 9 156023171 Spacer Spool Holder D 50 H 30 1 1 10 F1 056092097 Fuse 2A 250V 5 x 20 T 1 1 11 356029240...

Страница 59: ...1 1 36 Z 057098023 Choke MigMatic 380 D 8 50 L 305 1 1 37 CB1 056067283 Circuit Breaker 5A 1 1 38 056092098 Holder Fuse 1 1 39 PC2 057084167 Circuit Board F O D 1 1 40 FM1 057035021 Fan 230VAC 1 1 41...

Страница 60: ...1 6 956142861 Rating Plate MigMatic 300DX V 230 400 1 6 956142859 Rating Plate MigMatic 380DX V 400 1 6 956142863 Rating Plate MigMatic 380DX V 230 400 1 7 000207291 Label Primary Power Connections 1...

Страница 61: ...029242 Nameplate Front Lower MigMatic 300 300DX 1 19 356029243 Nameplate Front Lower MigMatic 380 380DX 1 20 056067267 Switch Power 1 1 21 356029236 Nameplate Front Upper MigMatic 300DX 1 21 356029238...

Страница 62: ...w Ring 1 1 7 156015027 Spool Nut Plastic 1 1 8 156023170 Spacer Spool Holder D 50 H 18 1 1 9 156023171 Spacer Spool Holder D 50 H 30 1 1 10 F1 056092097 Fuse 2A 250V 5 x 20 T 1 1 11 000207076 Knob Poi...

Страница 63: ...mer 400V 60 x 70 x 150 AL 1 1 38 Z 057098023 Choke MigMatic 380 D 8 50 L 305 39 PC3 057084169 Circuit Board Burnback Time Slope Adjustment 1 1 40 056092098 Holder Fuse 1 1 41 PC1 057084170 Circuit Boa...

Страница 64: ...2 Handwheel Reel w Ring 1 1 7 156015027 Spool Nut Plastic 1 1 8 156023170 Spacer Spool Holder D 50 H 18 1 1 9 156023171 Spacer Spool Holder D 50 H 30 1 1 10 F1 056092097 Fuse 2A 250V 5 x 20 T 1 1 11 0...

Страница 65: ...own 1 1 37 T1 058021158 Transformer 400V 50 x 100 x 150 AL 1 1 38 Z 057098023 Choke MigMatic 380 D 8 50 L 305 1 39 PC3 057084169 Circuit Board Burnback Time Slope Adjustment 1 1 40 056092098 Holder Fu...

Страница 66: ...D x 0 437 OD x 0 15T STL PLN 3 5 173620 Bushing MTG Motor 3 6 221912 Guide Wire Inlet Nylon 023 052 1 7 010224 Pin Spring CS 187 x 1 000 1 8 225718 Fastener Pinned 1 9 196896 Cup Spring 1 10 196897 Sp...

Страница 67: ...3 Screw M8 x 35 1 24 156018024 Nut M8 1 25 156009080 Washer Lock 1 26 156090008 Washer Flat 1 27 656005031 Insulator Plate 1 28 756084028 Spacer MTG Motor 1 29 756033039 Bushing Snap in D 22 9 1 30 V5...

Страница 68: ...3 7 656005027 Insulator Motor 1 8 238728 Lever MTG Pressure Gear 1 9 238726 Housing Adapter Drive Motor 1 10 221654 Washer Shldr Insulating 2 11 156019200 Screw M6 x 35 2 12 173618 Carrier Drive Gear...

Страница 69: ...er Gear 4 27 151828 Pin Cotter Hair 042 x 750 2 28 079634 Pin Hinge 1 29 156019804 Screw 5 16 18 x 1 Alloy Steel Socket Head 1 30 156009145 Washer Flat 1 31 221912 Guide Wire Inlet Nylon 023 052 1 32...

Страница 70: ...72 000 U Grooved 056 192 1 2 mm 0 045 in 0 045 in 079 599 053 701 U Grooved 056 193 1 0 mm 0 035 in 0 035 in 079 606 132 958 V Knurled 056 192 1 2 mm 0 045 in 0 045 in 079 607 132 957 V Knurled 056 19...

Страница 71: ...or for a minimum of one year whichever is greater Induction Heating Power Sources Coolers and Electronic Controls Recorders Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Contro...

Страница 72: ...ry Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Suppl...

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