Miller Millermatic 350P Technical Manual
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Miller Millermatic 350P Technical Manual

Arc welding power source and wire feeder
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Millermatic 350 And
Millermatic 350P
TM-1327Q
Eff. w/ Serial Number LC447907
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)
2012−01

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  • Page 1 TM-1327Q 2012−01 Eff. w/ Serial Number LC447907 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 Visit our website at File: MIG (GMAW) www.MillerWelds.com...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ........1-1.
  • Page 4 TABLE OF CONTENTS 6-7. Recommended Crater Fill Parameters ........... 6-8.

  • Page 5: Section 1 − Safety Precautions For Servicing

    SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage OM-1327AH - 2012−01, safety_stm 2011−10 DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

  • Page 6: California Proposition 65 Warnings

    MOVING PARTS can injure. H.F. RADIATION can cause interference. D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and D Keep away from pinch points such as drive communications equipment. rolls.

  • Page 7: Section 2 − Introduction

    SECTION 2 − INTRODUCTION 2-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 2-2.

  • Page 8: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Specifications Max. Open Amps Input at Rated Output Circuit Rated Output 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*) (1.5*) (0.75*) (0.5*)

  • Page 9: 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 Millermatic 350 TM-1327 Page 5...

  • Page 10: Weld Output Terminals And Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-G 2009−08 TM-1327 Page 6...

  • Page 11: Connecting To Weld Output Terminals

    3-5. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) 803 778-A Correct Installation Incorrect Installation Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper Supplied Weld Output Terminal Nut...

  • Page 12: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Work Clamp Do not extend or downsize the work cable. Only use the work cable supplied with the unit. 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.

  • Page 13: Installing Welding Gun

    4-3. 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 14: Connecting Spoolmatic) 15A Or 30A Gun

    4-4. 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 15: Connecting Xr Edge, Xr-A Gun, Xr-A Python, Or Xr - Alumapro

    4-5. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - AlumaPro 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.

  • Page 16: Setting Gun Polarity For Wire Type

    4-6. 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 17: Installing Gas Supply

    4-7. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

  • Page 18: Installing Wire Spool And Adjusting Hub Tension

    4-8. Installing Wire Spool and Adjusting Hub Tension Use compression spring with 8 in. (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in. Ref. 805 023-A 4-9. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard.

  • Page 19: Selecting Input Voltage (200/230/460 Volt Models Only)

    4-10. Selecting Input Voltage (200/230/460 Volt Models Only) 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 20: Connecting 3-Phase Input Power

    4-11. Connecting 3-Phase Input Power = GND/PE Earth Ground Rear Panel Tools Needed: Ref. 803 543-E / 803 766-A available at site to be sure it matches conductor to disconnect device grounding Installation must meet all National and the voltage specified on the rating terminal first.

  • Page 21: Connecting 1-Phase Input Power

    4-12. Connecting 1-Phase Input Power =GND/PE Earth Ground Rear Panel Tools Needed: Ref. 803 543-E / 803 766-A Three Conductor Power Cord Preparation Disconnect Device Grounding Terminal Installation must meet all National and Local Codes - have only qualified Input Power Cord Strain Relief 10 Disconnect Device Line Terminals persons make this installation.

  • Page 22: Threading Welding Wire For Mig Gun

    4-13. Threading Welding Wire For MIG 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.

  • Page 23: Threading Welding Wire For Xr Edge, Xr-A Gun, Xr-A Python, Or Xr - Alumapro

    4-14. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - AlumaPro 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 IMPORTANT!

  • Page 24: Threading Welding Wire Through Xr Guns

    4-15. Threading Welding Wire Through XR Guns Welding wire is electrically live when gun trigger is used to jog wire. For XR-A Edge Gun: Refer to Section NO TAG for instruc- tions on feeding wire through welding power source. Pressure Roll Assembly Lay gun cable out straight.

  • Page 25: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. 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 pulse VOLTS illuminates in MIG welding mode Arc Control Button MIG module and is programmed for indicating volts in left display can be...

  • Page 26: Mig Mode

    The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off, whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized. 5-2.
  • Page 27 Notes Millermatic 350 TM-1327 Page 23...

  • Page 28: Weld Parameters For Mig Mode

    5-9. Weld Parameters For MIG Mode TM-1327 Page 24 Millermatic 350...

  • Page 29: Weld Parameters For Pulse Mode

    5-10. Weld Parameters For Pulse Mode Millermatic 350 TM-1327 Page 25...

  • Page 30: Section 6 − Programming

    SECTION 6 − PROGRAMMING 6-1. 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. Adjust left MIG welding mode: Depress...

  • Page 31: Pulse Mig Welding Mode

    6-2. 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 32: Timers

    6-3. 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 33: Arc Times, Arc Starts, Hot Start, Set Up Push/Pull Motor Torque (Sup) (Aluminum Pulse Only), And Crater Fill

    6-4. Arc Times, Arc Starts, Hot Start, Set Up Push/Pull Motor Torque (SUP) (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, Motor Calibration, and SUP function. The software version data and motor calibration function are for use by factory authorized service personnel only.

  • Page 34: Setting Hot Start (Aluminum Pulse Only) Parameters

    6-5. 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 If starts are cold or made inactive when set to Off if starts are too hot. Ref.

  • Page 35: Setting Crater Fill

    6-6. 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. For example, if a MIG gun is using the .035 steel pulse program, and crater fill is on and parameters are set, crater will also be on and the same parameters will be set for a stainless pulse program.

  • Page 36: Recommended Crater Fill Parameters

    6-7. 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) TM-1327 Page 32 Millermatic 350...
  • Page 37 3/8” 1/4” 3/16” 1/8” 19ga. 20ga. (1.05mm) (0.9mm) SC-187 212-A Millermatic 350 TM-1327 Page 33...

  • Page 38: System Reset

    6-8. System Reset RTMR Accessing the System Reset function will also allow access to Timer Reset ( 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 39: Motor Calibration Function Prior To Serial No. Lh170741B

    6-9. Motor Calibration Function Prior To Serial No. LH170741B Ref. 213 935-A Perform this function after replacing wire Right Knob right knob while continuing to hold gun drive motor and/or control circuit board. trigger. Right Display motor calibration function Release gun trigger. Arc Control Button automatically calibrates the wire drive Simultaneously press Setup and Arc...

  • Page 40: Motor Calibration Function Eff W/Serial No. Lh170741B

    6-10. Motor Calibration Function Eff w/Serial No. LH170741B Ref. 213 935-A Perform this function after replacing wire Left Display Press and hold gun trigger. Wire drive speed will be overridden to 50 IPM for 12 drive motor and/or control circuit board. Right Knob motor calibration...

  • Page 41: Set Up Push Motor Torque (Sup)

    Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high. 6-11. Set Up Push Motor Torque (SUP) Ref. 213 935-A Setup Button buttons, and release buttons. The (SUP) setting will adjust the over-torque limit of the push motor inside Rotate the left knob counterclockwise Left Knob...

  • Page 42: Section 7 − Theory Of Operation

    SECTION 7 − THEORY OF OPERATION A. Block Diagram Theory of Operation is shown for the 200/230 volt models. Theory for other models is similar. Input Inductors Capacitors Power Switch S1 L1, L3, L4 C3, C4 Provides on/off control of welding power source.
  • Page 43 16 Wire Feed Motor M1 Feeds wire at speed set by Control board PC1. 17 Tach/Pulse Board PC6 Provides speed signal to wire feed motor and feedback signal to User Interface board PC3. Current Transformer 18 Optical Tach PC7 Output Main Transformer Diodes...
  • Page 44 B. Basic Training Circuit TM-1327 Page 40 Millermatic 350...
  • Page 45 This circuit is for training purposes only. It has been modified for that use and may not reflect the actual circuit for your unit 220 978-A Millermatic 350 TM-1327 Page 41...

  • Page 46: Section 8 − Pre-Power Troubleshooting

    SECTION 8 − PRE-POWER TROUBLESHOOTING 8-1. Checking Unit Before Applying Power See Section 9-3 for test points and values and Section 12 for parts location. Discharge input capacitors according to Section 8-2 and be sure voltage is near zero before touching any parts. Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.

  • Page 47: Measuring Input Capacitor Voltage (200/230/460 V Model Shown)

    8-2. Measuring Input Capacitor Voltage (200/230/460 V Model Shown) Turn Off welding power source, and disconnect in- put power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.

  • Page 48: Output Diodes

    8-3. Output Diodes D1, D2 Read and follow safety information in Section 8-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power checks. Remove wrist strap before perform- ing any checks or proce- dures with power applied to the machine.

  • Page 49: Input Rectifier Sr1, Input Capacitors C3 And C4, And Resistors R11 And R12

    8-4. Input Rectifier SR1, Input Capacitors C3 And C4, And Resistors R11 And R12 (200/230/460 V Model Shown) Read follow safety information in Section 8-1 before proceeding. Wear an earth grounded wrist strap when performing pre-power checks. Remove wrist strap be- Input Capacitors C3, C4 fore performing any checks or procedures with power applied to...

  • Page 50: Igbt Modules Pm1, Pm2 (200/230/460 V Model Shown)

    Visually inspect PM1 and PM2 for damage. Disconnect gate lead plug PLG5 from receptacle RC5 on control board PC1. Use an IGBT tester (MILLER Part No. 043 553) as follows: A. Check two IGBT’s per module. B. Connect red clip to C.

  • Page 51: Diodes D1 And D2 (200/230/460 V Model Shown)

    8-6. Diodes D1 And D2 (200/230/460 V Model Shown) Read and follow safety information in Section 8-1 before proceeding. Wear an earth grounded wrist strap when performing Torque to 25 in./lbs (2.8 NVm) pre-power checks. Remove wrist strap before perform- Torque to 31 in/lbs (3.5 NVm) ing any checks or proce- dures with power applied to...

  • Page 52: Section 9 − Troubleshooting

    9-1. Troubleshooting Table See Section 9-3 for test points and values and Section 8 for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. See the Miller Extranet for service memos that may aid in the repair of this product.
  • Page 53 Always perform pre-power troubleshooting before applying power to unit (see Section 8). Trouble Remedy If gas flow is excessive, replace regulator. Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. Check main control board PC1 and connections, and replace if necessary (see Section 9-5). Fan motor FM not operating properly.

  • Page 54: Help Displays

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-2. Help Displays HELP HELP HELP HELP HELP HELP HELP HELP HELP SAVE HELP 350P HELP HELP Displays a jog wire feed speed. TM-1327 Page 50 Millermatic 350...
  • Page 55 Always perform pre-power troubleshooting before applying power to unit (see Section 8). Help 4 Help 9 All directions are in reference to the Indicates gun trigger was pulled and held for front of the unit. All circuitry referred to Indicates a malfunction in Pulse MIG 2 minutes without a welding arc established is located inside the unit.

  • Page 56: Troubleshooting Circuit Diagram For 200/230/460/575 V Models

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-3. Troubleshooting Circuit Diagram For 200/230/460/575 V Models Do Not Make Test Equipment Connections To These Points. Test Equipment Needed: TM-1327 Page 52 Millermatic 350...
  • Page 57 Always perform pre-power troubleshooting before applying power to unit (see Section 8). See Section 9-4 For Waveforms A And B V4 V5 V6 255 726-B Millermatic 350 TM-1327 Page 53...
  • Page 58 Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-3. Troubleshooting Circuit Diagram For 200/230/460/575 V Models (Continued) Resistance Values Tolerance − 10% unless specified  Turn Off unit and disconnect input Voltage Readings power before checking resistance Tolerance −...

  • Page 59: Waveforms For Sections

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-4. Waveforms For Sections 9-3 10 s 20 V 10 s 20 V A. DC Open-Circuit Voltage B. 25 Volts DC, 200 Amperes (Resistive Load) Test Equipment Needed: Millermatic 350 TM-1327 Page 55...

  • Page 60: Main Control Board Pc1 Testing Information (Prior To Le411272)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-5. Main Control Board PC1 Testing Information (Prior To LE411272) (Use With Section 9-6) Be sure plugs are secure before testing. See Section 9-6 for specific values during testing. Motor Control Board PC1 If no grease is present on items 6 (RC5) or 11 (RC11), grease connectors with Part No.

  • Page 61: Main Control Board Pc1 Test Point Values (Prior To Le411272)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-6. Main Control Board PC1 Test Point Values (Prior To LE411272) a) Tolerance −  10% unless specified PC1 Voltage Readings b) Reference − to circuit common (chassis ground) unless noted c) Triggered −...
  • Page 62 Always perform pre-power troubleshooting before applying power to unit (see Section 8). Receptacle Values enable agrnd command agrnd contactor agrnd wirefeed agrnd agrnd agrnd I FB agrnd Not used agrnd +15 volts DC agrnd −15 volts DC agrnd Not used Not used +35 volts DC +35 volts DC...
  • Page 63 Always perform pre-power troubleshooting before applying power to unit (see Section 8). Receptacle Values RC13 +2.5 to 22 volts DC with respect to RC13-3, spool gun trigger closed, and min to max of spool gun wire feed speed Not used +2.5 to 22 volts DC with respect to RC13-1, spool gun trigger closed, and min to max of spool gun wire feed speed RC14...

  • Page 64: Main Control Board Pc1 Testing Information (Eff. W/Le411272)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-7. Main Control Board PC1 Testing Information (Eff. w/LE411272) (Use With Section 9-8) Be sure plugs are secure before testing. See Section 9-8 for specific values during testing. Motor Control Board PC1 If not grease is present on items 6 (RC5) or 11 (RC11), grease connectors with Part No.

  • Page 65: Main Control Board Pc1 Test Point Values (Eff. W/Le411272)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-8. Main Control Board PC1 Test Point Values (Eff. w/LE411272) a) Tolerance −  10% unless specified PC1 Voltage Readings b) Reference − to circuit common (chassis ground) unless noted c) Triggered −...
  • Page 66 Always perform pre-power troubleshooting before applying power to unit (see Section 8). enable agrnd command agrnd contactor agrnd wirefeed agrnd agrnd agrnd I FB agrnd Not used agrnd +15 volts DC agrnd −15 volts DC agrnd Not used Not used +35 volts DC +35 volts DC Do not measure −...
  • Page 67 Always perform pre-power troubleshooting before applying power to unit (see Section 8). RC13 +2.5 to 22 volts DC with respect to RC13-3, spool gun trigger closed, and min to max of spool gun wire feed speed Not used +2.5 to 22 volts DC with respect to RC13-1, spool gun trigger closed, and min to max of spool gun wire feed speed RC64 Less than 1 ohm with respect to RC64-2...

  • Page 68: Interconnect Board Pc2 Testing Information (200/230/460 V Model Shown)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-9. Interconnect Board PC2 Testing Information (200/230/460 V Model Shown) (Use With Section 9-10) Be sure plugs are secure before testing. See Section 9-10 for specific values during testing. Display Board PC1 L Torque to 25 in/lbs (2.8 NVm) z Torque to 31 in/lbs (3.5 NVm)

  • Page 69: Interconnect Board Pc2 Test Point Values

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-10. Interconnect Board PC2 Test Point Values a) Tolerance −  10% unless specified PC2 Voltage Readings b) Reference − to circuit common (chassis ground) unless noted c) Triggered − means gun trigger is pressed Receptacle Values...

  • Page 70: User Interface Board Pc3 Testing Information (Use With Section 9-12)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-11. User Interface Board PC3 Testing Information (Use With Section 9-12) Be sure plugs are secure before testing. See Section 9-12 for specific values during testing. User Interface Board PC3 Receptacle RC2 Receptacle RC3 Receptacle J3...

  • Page 71: User Interface Board Pc3 Test Point Values

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-12. User Interface Board PC3 Test Point Values a) Tolerance −  10% unless specified PC3 Voltage Readings b) Reference − to circuit common (chassis ground) unless noted c) Triggered −...

  • Page 72: Pulse/Tach Board Pc6 Testing Information (Use With Section 9-14)

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-13. Pulse/Tach Board PC6 Testing Information (Use With Section 9-14) Be sure plugs are secure before testing. See Section 9-14 for specific values during testing. Pulse/Tach Board PC3 Test Equipment Needed: 216 344-B / Ref.

  • Page 73: Pulse/Tach Board Pc6 Test Point Values

    Always perform pre-power troubleshooting before applying power to unit (see Section 8). 9-14. Pulse/Tach Board PC6 Test Point Values a) Tolerance −  10% unless specified PC6 Voltage Readings b) Reference − to circuit common (chassis ground) unless noted c) Triggered − means gun trigger is pressed Receptacle Values...

  • Page 74: Section 10 − Maintenance

    Check for rubber washers on PC2 encoder shafts, if washers are not present, add Part No. 234 197 to encoder shafts. Contact Miller Service for information on adding weatherstripping adhesive, silicon caulk, polarity indicator seals, and contactor side shield seals to locations on machine.

  • Page 75: Changing Drive Roll And Wire Inlet Guide

    10-5. 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. Intermediate Guide .045 Groove .035 Groove Drive Roll The drive assembly comes equipped with factory installed .035/.045 combination drive rolls.

  • Page 76: Removing Fan Motor

    10-6. Removing Fan Motor Y Significant DC voltage can remain on capacitors after unit is Off. Always check capacitors according Section 8-2 or to be sure they have discharged before working on unit. Remove wrapper and lower left side panel from unit. Lower Bezel Remove bezel...

  • Page 77: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside machine case or contact distributor for more information. The following is a list of all diagrams for models covered by this manual. Model Serial Or Style Number Circuit Diagram...
  • Page 78 Figure 8-1. Circuit Diagram For 200/230 Or 460/575 V Model Welding Power Source Eff w/LC447907 Thru LE282543 TM-1327 Page 74 Millermatic 350...
  • Page 79 212 985-G Millermatic 350 TM-1327 Page 75...
  • Page 80 Figure 8-2. Circuit Diagram For 200/230/460 V Model Welding Power Source Eff w/LE423450 Thru LJ231477B TM-1327 Page 76 Millermatic 350...
  • Page 81 224 242-B Millermatic 350 TM-1327 Page 77...
  • Page 82 Figure 8-3. Circuit Diagram For 200/230/460 V Model Welding Power Source Eff w/LJ231478B And Following TM-1327 Page 78 Millermatic 350...
  • Page 83 237 991-A Millermatic 350 TM-1327 Page 79...
  • Page 84 Figure 8-4. Circuit Diagram For 460/575 V Model Welding Power Source Eff w/LE411272 Thru LJ231477B TM-1327 Page 80 Millermatic 350...
  • Page 85 223 926-B Millermatic 350 TM-1327 Page 81...
  • Page 86 Figure 8-5. Circuit Diagram For 460/575 V Model Welding Power Source Eff w/LJ231478B And Following TM-1327 Page 82 Millermatic 350...
  • Page 87 237 992-A Millermatic 350 TM-1327 Page 83...
  • Page 88 Figure 8-6. Circuit Diagram For 200/230/460/575 V Model Welding Power Source Eff w/MA020053B Thru MC061225N TM-1327 Page 84 Millermatic 350...
  • Page 89 246 030-B Millermatic 350 TM-1327 Page 85...
  • Page 90 Figure 8-7. Circuit Diagram For 200/230/460/575 V Model Welding Power Source Eff w/MC061226N And Following TM-1327 Page 86 Millermatic 350...
  • Page 91 255 726-B Millermatic 350 TM-1327 Page 87...
  • Page 92 Notes TM-1327 Page 88 Millermatic 350...
  • Page 93 MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 350 And Millermatic 350P Eff w/LC447907 Thru LE443589 For OM-1327 (213 814) Revisions A Thru H Visit our website at File: MIG (GMAW) www.MillerWelds.com...

  • Page 94: Section 12 − Parts List (Eff W/Lc447907 Thru Le443589)

    SECTION 12 − PARTS LIST (Eff w/LC447907 Thru LE443589) Hardware is common and not available unless listed. 803 545-A Figure 12-1. Main Assembly TM-1327 Page 90 Millermatic 350...
  • Page 95 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ... . . 212829 DOOR,ACCESS WIRE COMPARTMENT .......
  • Page 96 Hardware is common and not available unless listed. 803 546-A Figure 12-2. Baffle, Center w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-2. Baffle, Center w/Components (Fig 12-1 Item 7) ... . 058427 RING,RETAINING SPOOL .
  • Page 97 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Baffle, Center w/Components (Fig 12-1 Item 7) (Continued) ..211055 CIRCUIT CARD ASSY,CONTROL W/PROGRAM (Prior to LE243469) ..220522 CIRCUIT CARD ASSY,CONTROL W/PROGRAM (200/230V model) (Eff w/LE243469)
  • Page 98 Hardware is common and not available unless listed. 13 14 803 552-A Figure 12-3. Inverter Assy Item Dia. Part Mkgs. Description Quantity Figure 12-3. Inverter Assy (Fig 12-1 Item 9) ..188634 CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/COVER .
  • Page 99 Item Dia. Part Mkgs. Description Quantity Figure 12-3. Inverter Assy (Fig 12-1 Item 9) (Continued) ..211125 CIRCUIT CARD ASSY,INTERCONNECT (200/230) ..... .
  • Page 100 Hardware is common and not available unless listed. 803 547-C Figure 12-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-4. Panel, Front w/Components (Fig 12-1 Item 23) ... . . 212837 HANDLE, .
  • Page 101 Hardware is common and not available unless listed. 803 549-A Figure 12-5. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-5. Panel, Rear w/Components (Fig 12-1 Item 10) ... . . 212820 PANEL,REAR .
  • Page 102 See Table 10-1 Hardware is common and not available unless listed. Drive Roll & Wire Guide Kits. 803 548-B Figure 12-6. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-6. Wire Drive Assembly 213137 ... . . 216409 .
  • Page 103 Item Dia. Part Mkgs. Description Quantity 213137 Figure 12-6. Wire Drive Assembly (Continued) ... . . 221 654 ..WASHER,SHLDR INSULATING (Eff w/LE350335) ..... .
  • Page 104 Item Number Figure 12-7. Consumables Flowchart TM-1327 Page 100 Millermatic 350...
  • Page 105 Item Part Description Quantity Figure 12-7. Consumables Flowchart Table 10-2. Nozzles ... . NOZZLE, spot flat (requires diffuser 209099, used with any 176238 heavy duty FasTipt contact tip) ........
  • Page 106 Item Part Description Quantity Figure 12-7. Consumables Flowchart (Continued) Table 10-5. Tapered FasTipt Contact Tips* ... . .023 in (0.6 mm) ........... . 209024 .
  • Page 107 Item Part Description Quantity Figure 12-7. Consumables Flowchart (Continued) Table 10-10. Goosenecks ... +199 625 GOOSENECK, jacketed 4.5 in/50deg wrench swivel (standard on 300 & 400 amp models) ........
  • Page 108 For consumable items 1 thru 7 see Figure 12-7. 802 630-C Figure 12-8. 4012 Gun TM-1327 Page 104 Millermatic 350...
  • Page 109 ....199 663 KIT, adapter Miller to old Hobart/Thermal/Tweco (includes) .......
  • Page 110 Notes TM-1327 Page 106 Millermatic 350...
  • Page 111 MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 350 And Millermatic 350P Eff w/LE443590 Thru LJ420782B For OM-1327 (213 814) Revision J Thru Revision Y Visit our website at File: MIG (GMAW) www.MillerWelds.com...

  • Page 112: Section 13 − Parts List (Eff W/Le443590 Thru Lj420783B)

    SECTION 13 − PARTS LIST (Eff w/LE443590 Thru LJ420783B) Hardware is common and not available unless listed. 803 545-C Figure 13-1. Main Assembly TM-1327 Page 108 Millermatic 350...
  • Page 113 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly ... . . 212829 DOOR,ACCESS WIRE COMPARTMENT .......
  • Page 114 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly (Continued) ....210925 REGULATOR/FLOWMETER,0−50 CFH AR/CO2 W/FLOWTUBE(350P MODEL) (Prior to LH490000B) .....
  • Page 115 Hardware is common and not available unless listed. 803 546-C Figure 13-2. Baffle, Center w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-2. Baffle, Center w/Components (Fig 13-1 Item 7) ... . 058427 RING,RETAINING SPOOL .
  • Page 116 Item Dia. Part Mkgs. Description Quantity Figure 13-2. Baffle, Center w/Components (Fig 13-1 Item 7) (Continued) ... 204310 STAND−OFF,NO 6−32 X .437 LG .250 HEX AL M&F ....
  • Page 117 Hardware is common and not available unless listed. 803 552-A Figure 13-3. Inverter Assy Item Dia. Part Mkgs. Description Quantity Figure 13-3. Inverter Assy (Fig 13-1 Item 9) ..188634 CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/COVER .
  • Page 118 Item Dia. Part Mkgs. Description Quantity Figure 13-3. Inverter Assy (Fig 13-1 Item 9) (Continued) ..C3,4 192935 CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA (200/230/460 MODELS) ..........
  • Page 119 Hardware is common and not available unless listed. 803 547-C Figure 13-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-4. Panel, Front w/Components (Fig 13-1 Item 23) ... . . 212837 HANDLE, .
  • Page 120 Hardware is common and not available unless listed. 803 549-B Figure 13-5. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-5. Panel, Rear w/Components (Fig 13-1 Item 10) ... . . 212820 PANEL,REAR .
  • Page 121 See Table 11-1 Hardware is common and not available unless listed. Drive Roll & Wire Guide Kits. 803 548-C Figure 13-6. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 13-6. Wire Drive Assembly 213137 ... . . 223541 .
  • Page 122 Item Dia. Part Mkgs. Description Quantity 213137 Figure 13-6. Wire Drive Assembly (Continued) ... . . 089800 ..NUT, 250−20 .44HEX .22H STL PLD .58D FLANGE DEFOR .
  • Page 123 MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 350 And Millermatic 350P Eff w/LJ420783B And Following For OM-1327 (213 814) Revision Z And Following Visit our website at File: MIG (GMAW) www.MillerWelds.com...

  • Page 124: Section 14 − Parts List (Eff W/Lj420783B And Following)

    SECTION 14 − PARTS LIST (Eff w/LJ420783B And Following) Hardware is common and not available unless listed. 803 545-D Figure 14-1. Main Assembly TM-1327 Page 120 Millermatic 350...
  • Page 125 Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly ... . . 212829 DOOR,ACCESS WIRE COMPARTMENT .......
  • Page 126 Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly (Continued) ....234263 REGULATOR/FLOWMETER, 0−50 CFH AR/CO2/MIX W/FILTER ............
  • Page 127 Hardware is common and not available unless listed. 803 546-D Figure 14-2. Baffle, Center w/Components Item Dia. Part Mkgs. Description Quantity Figure 14-2. Baffle, Center w/Components (Fig 14-1 Item 7) ... . 058427 RING,RETAINING SPOOL .
  • Page 128 Item Dia. Part Mkgs. Description Quantity Figure 14-2. Baffle, Center w/Components (Fig 14-1 Item 7) (Continued) ... 204310 STAND−OFF,NO 6−32 X .437 LG .250 HEX AL M&F ....
  • Page 129 Hardware is common and not available unless listed. 803 552-A Figure 14-3. Inverter Assy Item Dia. Part Mkgs. Description Quantity Figure 14-3. Inverter Assy (Fig 14-1 Item 9) ..188634 CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/COVER .
  • Page 130 Item Dia. Part Mkgs. Description Quantity Figure 14-3. Inverter Assy (Fig 14-1 Item 9) (Continued) ..C3,4 192935 CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA (200/230/460 MODELS) ..........
  • Page 131 Hardware is common and not available unless listed. Ref. 803 547-C Figure 14-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 14-4. Panel, Front w/Components (Fig 14-1 Item 23) ... . . 212837 HANDLE, .
  • Page 132 Hardware is common and not available unless listed. 803 549-B Figure 14-5. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 14-5. Panel, Rear w/Components (Fig 14-1 Item 10) ... . . 212820 PANEL,REAR .
  • Page 133 See Table 12-1 Hardware is common and not available unless listed. Drive Roll & Wire Guide Kits. 803 548-G Figure 14-6. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 14-6. Wire Drive Assembly ... . . 223541 .
  • Page 134 ... . . 108943 ..SCREW,250−20X1.50 HEXWHD.61D GR5 PLD ..... . .
  • Page 135 Notes...
  • Page 136 An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co.

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