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Miller Electric Millermatic 350 manual

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Table of contents for the manual

  • Page 1

    Millermatic 350 And Millermatic 350P Processes Description R Arc W elding Power Source and Wire Feeder OM-1327 213 814X 2007−1 1 MIG (GMAW ) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) W elding R File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 5 − PROGRAMMING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. MIG Welding Mode 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Pulse MI[...]

  • Page 5

    OM-1327 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or e[...]

  • Page 6

    OM-1327 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor ,[...]

  • Page 7

    OM-1327 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-1327 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lea[...]

  • Page 9

    OM-1327 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. L[...]

  • Page 10

    OM-1327 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUD[...]

  • Page 11

    OM-1327 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants méd[...]

  • Page 12

    OM-1327 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher de[...]

  • Page 13

    OM-1327 Page 9 2-5. P ri nci pa les n or m es de s éc ur ité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Wel[...]

  • Page 14

    OM-1327 Page 10[...]

  • Page 15

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications Rated Output Max. Open Circuit 60 Hz Amps Input at Rated Output Rated Output Circuit V oltage 60 Hz 200 V 230 V 460 V 575V KV A KW 300 A at 32 VDC, 60% Duty 350 A at 32 VDC, 40% Duty 90 Single-Phase 69 (1.7*) 61 (1.5*) 30 [...]

  • Page 16

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 12 3-3. V olt-Ampere Curve 217 443-A 1 Normal V olt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. MAX V OL TS MI N V OL TS[...]

  • Page 17

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 13 3-5. Installing Work Clamp 1 Work Cable 2 Boot Route cable through front panel opening. Slide boot onto work cable. 3 Negative (−) Output T erminal Connect cable to terminal and cover connection with boot. Close door . 803 540-B T ools Ne e d e d : 3/4 in 3 2 1 3-6. Ins[...]

  • Page 18

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 14 3-7. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun en d through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). T ighten knob. 4 Gun Trigger Plug Insert plug into rece[...]

  • Page 19

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 15 3-8. Connecting Spoolmatic ) 15A Or 30A Gun 803 568-C 1 Gu n Trigger Plug Insert plug into receptacle, and tighten threaded collar . 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose through opening in front panel. 4 Positive Weld Output T erminal Connect we[...]

  • Page 20

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 16 3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro 803 569-A / Ref. 803 570 -A / Ref. 803 463 . XR E dge guns p rior to serial n o. LE079101 require an a dapter cor d (par t no. 195 498) . 1 Gun End 2 Gun Liner 3 Wire Outlet Guide T rim excess liner from en[...]

  • Page 21

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 17 3-10. Setting Gun Polarity For Wire T ype 1 Polarity Changeover Information Always read and follow manufacture’s recommended polarity . 1 3/4, 1 1/16 in Ref. 803 541-A Changing Polarity D Wire Drive Assembly Lead Work Clamp Lead + Positive T erminal Shown as shipped −[...]

  • Page 22

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 18 3-1 1. Installing Gas Supply 803 542-B T ools Ne e d e d : 1-1/8, 5/8 in 1 2 3 4 5 7 Rear Panel 6 Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove cap, stand to s[...]

  • Page 23

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 19 3-12. Installing Wire Spool and Adjusting Hub T ension 072573-B When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. T ools Needed: 3-13. Electrical Service Guide Failure to fo llow these electrical servic[...]

  • Page 24

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 20 3-14. Selecting Input V oltage (200/230/460 V olt Models Only) 803 539-B / 804 042-A ! T urn Off welding power source, disconnect input power , and check voltage on input capacitors according to Section 6-3 before proceeding. . Check input voltage available at site. . Inc[...]

  • Page 25

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 21 3-15. Selecting A Location And Connecting 3-Phase Input Power Ref. 803 543-D / 803 766-A ! Installation must meet all National and Local Codes - have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conduct[...]

  • Page 26

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 22 3-16. Selection A Location And Connecting 1-Phase Input Power Ref. 803 543-D / 803 766-A T ools Needed: 3 2 7 6 4 ! Installation must meet all National and Local Codes - have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before[...]

  • Page 27

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 23 3-17. Threading W elding Wire For MIG Gun 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 6 in (150 mm) . Hold wire tightly [...]

  • Page 28

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 24 3-18. Threading W elding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Drive Roll 5 Intermediate Wire Guide 6 Outlet Wire Guide 7 Pressure Adjustment Knob 8 Gun Conduit Cable Lay gun cable out straight. T ools [...]

  • Page 29

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 25 3-19. Threading W elding Wire Through XR Guns Ref. 802 193-A / 801 556 / Ref. 151 666-C T ools Ne e d e d : ! W elding wire is electrically live when gun trigger is used to jog wire. . Refer t o Section 3-18 for instructions on feeding wire through welding pow- er source.[...]

  • Page 30

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 26 SECTION 4 − OPERA TION 4-1. Controls 1 Pulse Indicator Light . Pulse only lights if unit has the pulse MIG module and is programmed for pulse MIG. 2 MIG Indicator Lights Pulse (1) and MIG (2) illuminate to Indicate weld mode of unit. 3 Process Light PROCESS illuminates [...]

  • Page 31

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 27 because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed, then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before shutting off. If gun trigger is[...]

  • Page 32

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 28 4-9. W eld Parameters For MIG Mode Material Steel Steel Aluminum Stainless Steel Gas 100% Co 2 75% Argon 25% Co 2 90% Helium 7.5% Argon 2.5% Co 2 100% Argon Wire 1/2” 3/8” 1/4” 3/16” 1/8” 14ga 16ga 18ga 20ga 22ga 3/64 5356 24.0/535 23.5/500 22.5 /465 21.0 /375 1[...]

  • Page 33

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 29 4-10. W eld Parameters For Pulse Mode .045 .045 3/644043 3/645356 .0355356 WELDCHARTS 3/16" (4.8mm) 1/8" (3.2mm) 14ga (2.0mm) 16ga (1.6mm) 18ga (1.2mm) 19ga (1.0mm) 22ga (0.8mm) Gas Wire Material 90%Argon 10%Co 2 .035 Steel Ar/He/CO2 Tri−M[...]

  • Page 34

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 30 SECTION 5 − PROGRAMMING 5-1. MIG Welding Mode When the MIG light (2) is illuminated, the unit is in MI G W elding mode. SETUP T o enter MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select th e gun being used. S[...]

  • Page 35

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 31 5-2. Pulse MIG Welding Mode When the PULSE MIG (1, 2) is illuminated, the unit is in Pulse MIG W elding mode. SETUP T o enter Pulse MIG welding mode, depress the SETUP (6) button once to go to GUN selection. Rotate the right knob (9) to select th e gun being used. Select [...]

  • Page 36

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 32 5-3. Timers T o enter the TIMERS (5) menu depress the SETUP (6) button 4 times or until the TIMERS light (5) is illuminated. Items that can be adjusted in this menu are: Run-in speed ( R-IN ) − The speed of the wire prior to the welding arc being struck. This setting is[...]

  • Page 37

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 33 5-4. Arc T imes, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill Arc times and number of arc starts are saved in unit memory . T o view this information, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show arc h[...]

  • Page 38

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 34 5-5. Setting Hot Start (Aluminum Pulse Only) Parameters T o access the Setup Feature Menu, press both SETUP (1) and ARC CONTROL (2) buttons at the same time. Left display will initially show arc hours. Rotate left knob (3) until AL ST appears in the left display . Rotate [...]

  • Page 39

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 35 5-6. Setting Crater Fill T o set Crater Fill, select a program and press SETUP (1) until the TIMERS LED turns on. Press SETUP again and the left display will show CRTR and the right display will show OFF . Rotate right knob (3) to turn crater ON . Rotate left knob (2) to [...]

  • Page 40

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 36 5-7. Recommended Crater Fill Parameters 1/2" (12.7mm) What P r o c e s s a re Y ou U si n g? What Ma ter ia l a re Y ou W el d i n g? Su ggested Wire T y pe s Su ggested Shieldin g G ase s Wire S i z e s (Dia meter) Recommended C r a t er P a r a m e t e r s P U L S [...]

  • Page 41

    . A complete Parts List is available at www .MillerW elds.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

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 38 5-8. System Reset A system reset function is available that completely resets unit back to all the original factory settings. T o access this menu, turn on welding power source, then press the SETUP (1) button when the SETUP light illuminates under the Left display . SRS [...]

  • Page 43

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 39 5-9. Motor Calibration Function Perform this function after replacing wire drive motor and/or control circuit board. The motor calibration function automatically calibrates the wire drive motor to enhance arc starting performance and consistency . . T o obtain the most ac[...]

  • Page 44

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 40 . W elding wire birdnesting at the welding power source drive rolls may occur if this value is set too high. 5-10. Set Up Push Motor T orque (SUP) Or Reset (rES) 1 Setup Button 2 Left Knob 3 Left Display 4 Right Knob 5 Right Display 6 Arc Control Button Simultaneous ly p [...]

  • Page 45

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 41 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions . n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3 M[...]

  • Page 46

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 42 221 044-A / Ref. 803 550-A ! 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 Of f welding power source and disconnect input power . Remove case. 1 Input Capa[...]

  • Page 47

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 43 6-4. Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T i gh ten screw . 3 Intermediate Guide 4 Drive Roll . The drive assembly comes equipped with factory installed[...]

  • Page 48

    . A complete Parts List is available at www .MillerW elds.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 SA VE MM 350P A V MM 350 A V JOG A V HELP 7 A V HELP 1 1 Displays a jog wire feed speed. XXX[...]

  • Page 49

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 45 SC-187 212-A . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. S Help 0 Indicates overheating on left side of unit (displays flash between OVER TEMP and HELP 1). Unit will shutdown until internal temperature [...]

  • Page 50

    . A complete Parts List is available at www .MillerW elds.com OM-1327 Page 46 6-6. T roubleshooting T rouble 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 [...]

  • Page 51

    OM-1327 Page 47 Notes[...]

  • Page 52

    OM-1327 Page 48 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For 200V/230V/460V Models[...]

  • Page 53

    OM-1327 Page 49 224 242-B[...]

  • Page 54

    OM-1327 Page 50 Figure 7-2. Circuit Diagram For 460V/575V Models[...]

  • Page 55

    OM-1327 Page 51 223 926-B[...]

  • Page 56

    OM-1327 Page 52 SECTION 8 − P ARTS LIST 8-1. Drive Roll And Wire Guide Kits . Base selection of drive rolls upon the following recommended usages: 1 V -Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V -Knurled rolls for hard [...]

  • Page 57

    Notes[...]

  • Page 58

    Notes[...]

  • Page 59

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expert[...]

  • Page 60

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Hea dquart e rs[...]