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Miller Electric 300 - page 1
AC/DC, 300/200 AC/DC, 225, And 300 Processes Description Arc W elding Power Source OM-316 087 083Q August 2004 Thunderbolt XL R Stick (SMAW) W elding 225 And 300 Models: AC/DC, 300/200 AC/DC Models: Visit our website at www.MillerWelds.com ...
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Miller Electric 300 - 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 catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld ...
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Miller Electric 300 - 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 . . . . . . . ...
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Miller Electric 300 - page 4
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Miller Electric 300 - page 5
OM-316 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch Out! ...
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Miller Electric 300 - page 6
OM-316 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z8 ...
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Miller Electric 300 - page 7
OM-316 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 A ...
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Miller Electric 300 - page 8
OM-316 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W eld ...
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Miller Electric 300 - page 9
OM-316 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signifie « NOT ...
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Miller Electric 300 - page 10
OM-316 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. D Porter un masque de soudage mu ...
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Miller Electric 300 - page 11
OM-316 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au − dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcha ...
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Miller Electric 300 - page 12
OM-316 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443 − 9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Pipi ...
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Miller Electric 300 - page 13
OM-316 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Single Phase Do Not Switch Under Load Input On Of f Output Hz Hertz Alternating Current Electrode Positive Electrode Negative Direct Current W elding Arc V V olts W ork Electrode 3-2. Manufacturer ’ s Rating Labels 217 652-A / 165 371-A Rating Label For EN/FR Machines ...
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Miller Electric 300 - page 14
OM-316 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications AC/DC Models Mode Rated W elding Output Amperage Range Maximum Open- Circuit Amperes Input at Rated Load Output 50 Or 60 Hz, Single-Phase We i g ht Mode Output Range Ci rcu i t V oltage 1 15 V 220 V 230 V 400 V 460 V W eight AC 225 A @ 25 V olts AC, 20% Duty Cycle @ 60 Hz; 15% Duty Cyc ...
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Miller Electric 300 - page 15
OM-316 Page 1 1 4-2. Duty Cycle Charts A. For AC/DC Models 2 Minutes W elding 8 Minutes Resting 086 727 / 099 602-A Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 2 0% Duty Cycle at 225 Amperes. Ex- ceeding duty cycle can damage unit and void warranty . B. For 220, 230/400, And 460 V olt Models (300/2 ...
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Miller Electric 300 - page 16
OM-316 Page 12 4-3. V olt-Ampere Curves A. For AC/DC Models 193 509 / 193 510 / 193 51 1 / 193 512 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 1 15/230, 230 And 460 V olt Models (225/150 Amperes) B. For 220, 230/400, And 460 V olt Mode ...
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Miller Electric 300 - page 17
OM-316 Page 13 B. For AC Models 193 508 / 193 513 / 193 51 1 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 1 15/230 And 230 V olt Models (225 Amperes) B. For 220 V olt Model (300 Amperes) C. For 230/400 V olt Model (300 Amperes) 0 10 20 ...
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Miller Electric 300 - page 18
OM-316 Page 14 4-4. Selecting A Location 217 652-A / 802 105 1 Rating Label (See Section 3-2 ) Locate unit near correct input power . Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. 18 in (457 mm) for airflow 1 V A KW Hz LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRAN ...
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Miller Electric 300 - page 19
OM-316 Page 15 4-5. Installing Electrode Holder And Work Clamp 802 251 / 802 105-C Y T urn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through access hole and slide barrel away from electrode holde ...
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Miller Electric 300 - page 20
OM-316 Page 16 4-7. Electrical Service Guide Input V oltage 11 5 220 230 400 460 Input Amperes At Rated Output 95 [70] 47.5 [67] [39] 23.7 [34] Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 150 [1 10] 70 [100] [60] 35 [50] Min Input Conductor Size In A WG/Kcmil 8 [8] 12 [10] [14] 14 [14] Max Recommended Input Conductor Length I ...
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Miller Electric 300 - page 21
OM-316 Page 17 4-8. Internal Connections For Operating 1 15/230 V olts, 225 Amperes AC And AC/DC Models From 1 15 V olts Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. NOTE Y T urn Off unit and disconnect input power . 1 W rapper Remove wrapper . 2 Jump ...
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Miller Electric 300 - page 22
OM-316 Page 18 4-9. Internal Connections For Operating 230/400 V olts, 300/200 Amperes AC/DC Or 300 Amperes AC Models From 230 V olts Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. NOTE Ref. 802 247-D 1 2 3 4 5 6 7 2 3 5 6 Connected For 400 V olts Conne ...
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Miller Electric 300 - page 23
OM-316 Page 19 4-10. Connecting Input Power Ref. 802 246 For Models Supplied With Plug Y Disconnect and lockout/tag- ou t input power before instal- ling receptacle. Y Have only qualified persons make this installation. See rating label in Section 4 -4, and be sure to supply correct in- put power . 1 Proper Receptacle (User-Supplied) Receptacle mus ...
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Miller Electric 300 - page 24
OM-316 Page 20 SECTION 5 − OPERA TION 5-1. Controls A. Controls For AC/DC Models Ref. 217 857-B / 802 105-C 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of dc output, Electrode Posi- tive/DCEP (+),or Electrode Nega- tive/DCEN ( − ). For AC Weld Output Use mode switch to select ...
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Miller Electric 300 - page 25
OM-316 Page 21 B. Controls For AC Models Ref. 218 237-A / 802 105-C 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac low range o r high range output. 1 3 2 ...
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Miller Electric 300 - page 26
OM-316 Page 22 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Repair Or Replace Cracked Cables 6 Months 12 Months Blow Out Or V acuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block (See Section 6-2) 6-2. Lubricating Shunt Block ...
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Miller Electric 300 - page 27
OM-316 Page 23 6-3. Reinstalling Amperage Adjustment Indicator Ref. 218 237-A / 802 248-C Y T urn Off welding power source and disconnect input power . 1 W rapper Remove wrapper from unit. 2 Crank Handle 3 Shunt Shaft 4 Transformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft protruding through front panel and turn crank han ...
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Miller Electric 300 - page 28
OM-316 Page 24 6-4. T roubleshooting T rouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 4-10 ). Check and replace line fuses if open. Reset breakers if necessary (see Section 4-10 ). Fan does not run; weld output okay . Be sure nothing is blocking movement of fan. If fan does not run free ...
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Miller Electric 300 - page 29
OM-316 Page 25 SECTION 7 − ELECTRICAL DIAGRAMS 191 364 Figure 7-1. Circuit Diagram For AC/DC (230 V olts) Models 191 365 Figure 7-2. Circuit Diagram For AC/DC (460 V olts) Models ...
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Miller Electric 300 - page 30
OM-316 Page 26 191 363-A SEC T1 S2 WORK ELECTRODE R Z1 SR1 CONNECTED FOR 230 VOL TS PRI GRN S1 1 23 4 CONNECTED FOR 1 15 VOL TS PRI T1 12 3 4 PLG1 FM FM S1 GRN S1 PLG1 LINE (BLK) NEUTRAL (WHT) Figure 7-3. Circuit Diagram For AC/DC (1 15/230 V olts) Models 191 368 220 PRI SEC T1 GRN VOL T ONL Y S2 WORK ELECTRODE R Z1 SR1 S.O.P . POWER CORD FM S1 S.O ...
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Miller Electric 300 - page 31
OM-316 Page 27 191 369 SEC S2 WORK ELECTRODE R Z1 SR1 CONNECTED FOR 400 VOL TS PRI T1 GRN S1 230V 12 3 4 4 CONNECTED FOR 230 VOL TS PRI T1 13 2 POWER CORD FM FM Figure 7-5. Circuit Diagram For 300/200 AC/DC (230/400 V olts) Models 191 370 SEC T1 S.O.P . S2 WORK ELECTRODE R Z1 SR1 S.O.P . 460 PRI GRN VOL T ONL Y 230V POWER CORD FM S1 Figure 7-6. Cir ...
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Miller Electric 300 - page 32
OM-316 Page 28 191 362 WORK 230 PRI SEC T1 GRN VOL T ONL Y S2 AC HIGH AC LOW ELECTRODE PLG1 FM S1 Figure 7-7. Circuit Diagram For 225 (230 V olts) Models 191 361-A WORK CONNECTED FOR 230 VOL TS PRI SEC T1 GRN S2 ELECTRODE S1 1 23 4 CONNECTED FOR 1 15 VOL TS PRI T1 12 3 4 PLG1 FM FM GRN S1 PLG1 LINE (BLK) NEUTRAL (WHT) S1 Figure 7-8. Circuit Diagram ...
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Miller Electric 300 - page 33
OM-316 Page 29 WORK 220 PRI SEC T1 S.O.P . GRN VOL T ONL Y S2 AC HIGH AC LOW ELECTRODE POWER CORD FM S1 191 366 Figure 7-9. Circuit Diagram For 300 (220 V olts) Models 191 367 WORK CONNECTED FOR 400 VOL TS PRI SEC T1 GRN S2 ELECTRODE S1 230V 12 3 4 4 CONNECTED FOR 230 VOL TS PRI T1 13 2 POWER CORD FM FM Figure 7-10. Circuit Diagram For 300 (230/400 ...
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Miller Electric 300 - page 34
OM-316 Page 30 SECTION 8 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. W elding Methods 8-1. Shielded Metal Arc Welding (SMA W) Procedure 151 593 1 W orkpiece Make sure workpiece is clean before welding. 2 Work Clamp Place as close to the weld as possible. 3 Electrode A small diameter electrode requires less current than a large one. Fo ...
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Miller Electric 300 - page 35
OM-316 Page 31 8-2. Electrode And Amperage Selection Chart Ref. 087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRODE ...
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Miller Electric 300 - page 36
OM-316 Page 32 8-3. Striking An Arc S-0049 / S-0050 1 Electrode 2 W orkpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to work- piece, use a quick twist to free it. Bring electrode straight down to workpiece; then lift s ...
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Miller Electric 300 - page 37
OM-316 Page 33 8-5. W eld Bead Characteristics Ref. S-0052-B 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During W elding 4 Bad Overlap 5 Poor Penetration 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During W elding W eld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded. 4 No Overlap 5 Good Penetrati ...
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Miller Electric 300 - page 38
OM-316 Page 34 8-7. Electrode Movement During W elding S-0054-A 1 Stringer Bead − Steady Move- ment Along Seam 2 Weave Bead − Side T o Side Movement Along Seam 3 Weave Patterns Us e weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. . A single stringer bead is satis ...
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Miller Electric 300 - page 39
OM-316 Page 35 8-9. Lap Joints S-0063 / S-0064 1 Electrode 2 Single-Layer Fillet W eld Move electrode in circular motion. 3 Multi-Layer Fillet Weld W eld a second layer when a larger fillet i s n eeded. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 30 ° Or Less Single-Layer Fillet Weld Multi-Layer Fill ...
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Miller Electric 300 - page 40
OM-316 Page 36 T able 6-2. Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high Reduce arc length or voltage. T able 6-3. Incomplete ...
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Miller Electric 300 - page 41
OM-316 Page 37 T able 6-5. Excessive Penetration Good Penetration Excessive Penetration − weld metal melt- ing through base metal and hanging un- derneath weld. Excessive Penetration Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. T able 6-6. Burn ...
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Miller Electric 300 - page 42
OM-316 Page 38 SECTION 9 − P ARTS LIST 802 245-E . Hardware is common and not available unless listed. 31 Figure 9-1. Main Assembly (AC/DC model illustrated) ...
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Miller Electric 300 - page 43
OM-316 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 134 464 LABEL, warning general precautionary static&wire fe 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 217 732 LABEL, warning general precautionary (EN/FR) vert 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Miller Electric 300 - page 44
Notes ...
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Miller Electric 300 - page 45
Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual . ...
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Miller Electric 300 - page 46
TM-188 304 Page 2 Invision 354MP Notes ...
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Miller Electric 300 - page 47
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/04 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 expertise o ...
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Miller Electric 300 - page 48
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 W est S pencer Street Applet on, WI 5 4914 USA International He adquarter s − USA USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 9 20-735-4134 Int ernational F AX: 920-735-4125 European Headqua rters − United K ...
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