Miller MigMatic 300, MigMatic 380 Owner's Manual

OM-251958F 2018-02

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source

Wire Feeder

R

MigMatic 300/380 And DX

CE

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

OWNER’S MANUAL

File: MIG (GMAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

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

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − DEFINITIONS 5..................................................................

2-1. Additional Safety Symbols And Definitions 5................................................

2-2. Miscellaneous Symbols And Definitions 7..................................................

SECTION 3 − SPECIFICATIONS 8..............................................................

3-1. Serial Number And Rating Label Location 8................................................

3-2. Specifications 8........................................................................

3-3. Duty Cycle And Overheating 8...........................................................

3-4. Volt-Ampere Curves 9..................................................................

3-5. Environmental Specifications 10...........................................................

SECTION 4 − INSTALLATION 11................................................................

4-1. Installing Gas Supply 11.................................................................

4-2. Installing Wire Spool And Adjusting Hub Tension 12...........................................

4-3. Positioning Jumper Links (230/400V 3-Phase Models) 13......................................

4-4. Electrical Service Guide 14...............................................................

4-5. Connecting 3-Phase Input Power 16.......................................................

4-6. Changing Drive Rolls And Wire Inlet Guide (MigMatic 380 Models) 18...........................

4-7. Aligning Drive Rolls and Wire Guide 20.....................................................

4-8. Threading Welding Wire And Adjusting Pressure Roll Tension 21...............................

SECTION 5 − OPERATION 22...................................................................

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 Mode And Spot Time Selection (MigMatic 300 And 380 Models) 26.......................

5-6. Welding Wire Loading Settings (MigMatic 300 And 380 Models) 27..............................

5-7. Resetting Unit To Factory Default Settings (MigMatic 300 And 380 Models) 28....................

5-8. Controls For MigMatic 300DX 29..........................................................

5-9. Controls For MigMatic 380DX 30..........................................................

5-10. Burnback And Run-In Controls (DX Models Only) 31..........................................

5-11. Welding Power Source Input Line Voltage Adjustment (DX Models Only) 32......................

5-12. Welding Power Source Setup Menu (DX Models Only) 33.....................................

5-13. Trigger Mode Selection (DX Models Only) 34................................................

5-14. Welding Wire Diameter Selection For Synergic MIG (DX Models Only) 34........................

5-15. Welding Wire Type Selection For Synergic MIG (DX Models Only) 35............................

5-16. Gas Selection For Synergic MIG (DX Models Only) 35........................................

5-17. Selecting Manual MIG Welding (DX Models Only) 36..........................................

5-18. Selecting Synergic MIG Welding (DX Models Only) 37........................................

SECTION 6 − MAINTENANCE &TROUBLESHOOTING 38..........................................

6-1. Routine Maintenance 38.................................................................

6-2. Welding Gun And Wire Drive Assembly 38..................................................

6-3. Unit Overload 38........................................................................

6-4. Troubleshooting 39......................................................................

SECTION 7 − ELECTRICAL DIAGRAMS 40.......................................................

SECTION 8 − PARTS LIST 48...................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the prod
uct(s) identified in this declaration conform to the essential requirements and provisions of the stat
ed Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

MIGMATIC 300, 400VAC 029015540

MIGMATIC 300 DX, 400VAC 029015541

MIGMATIC 300, 230/400VAC 029015545

MIGMATIC 300 DX, 230/400VAC 029015546

MIGMATIC 380, 400VAC 029015542

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 Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

• IEC 60974-1:2012 Arc Welding Equipment – Part 1: Welding Power Sources

• IEC 60974-5:2007 Arc Welding Equipment – Part 5: Wire Feeders

• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements

EU Signatory:

July 1st, 2015

___________________________________________________________________________________

Massimigliano Lavarini Date of Declaration

ITW WELDING ITALY PRODUCTION MANAGER

956 172 215

EMF DATA SHEET FOR ARC WELDING POWER SOURCE

Product/Apparatus Identification

Product Stock Number

MIGMATIC 380, 400VAC 029015542

MIGMATIC 380 DX, 400VAC 029015543

MIGMATIC 380, 230/400VAC 029015547

MIGMATIC 380 DX, 230/400VAC 029015548

Compliance Information Summary

Applicable regulation Directive 2014/35/EU

Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC

Applicable standards IEC 62822−1:2016, IEC 62822−2:2016

Intended use

Non−thermal effects need to be considered for workplace assessment

Thermal effects need to be considered for workplace assessment

☒

☐

☐

Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations (if NO, specific required minimum distances apply)

Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed)

Occupational exposure is below the Action Levels (ALs) at the
standardized configurations (if applicable and NO, specific signage is needed)

EMF Data for Non−thermal Effects

Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)

Data is based on maximum power source capability (valid unless firmware/hardware is changed)

Data is based on worst case setting/program (only valid until setting options/welding programs are changed)

Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)

Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm

ELV EI @ standardized distance 0.06 0.02 0.02 0.02 0.03
Required minimum distance 1 cm 1 cm 1 cm 1 cm 1 cm

☒

for occupational use

Sensory

Effects

Head

☐

for use by laymen

Health

Effects

☐

☐

n.a

n.a

Trunk

☒

YES

☐

YES

☒

YES

☒

YES

☐

YES

Limb (hand) Limb (thigh)

☐

☒

☐

☐

☒

NO

NO

NO

NO

NO

Distance where all occupational ELV Exposure Indices fall below 0.20 (20%) 1 cm

Distance where all general public ELV Exposure Indices fall below 1.00 (100%) 10 cm

Tested by: Tony Samimi Date tested: 2017−02−20

956172333

EMF DATA SHEET FOR ARC WELDING POWER SOURCE

Product/Apparatus Identification

Product Stock Number

MIGMATIC 300, 400VAC 029015540
MIGMATIC 300 DX, 400VAC 029015541
MIGMATIC 300, 230/400VAC 029015545
MIGMATIC 300 DX, 230/400VAC 029015546

Compliance Information Summary

Applicable regulation Directive 2014/35/EU

Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC

Applicable standards IEC 62822−1:2016, IEC 62822−2:2016

Intended use

Non−thermal effects need to be considered for workplace assessment

Thermal effects need to be considered for workplace assessment

☒

☐

☐

Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations (if NO, specific required minimum distances apply)

Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed)

Occupational exposure is below the Action Levels (ALs) at the
standardized configurations (if applicable and NO, specific signage is needed)

EMF Data for Non−thermal Effects

Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)

Data is based on maximum power source capability (valid unless firmware/hardware is changed)

Data is based on worst case setting/program (only valid until setting options/welding programs are changed)

Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)

Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm

ELV EI @ standardized distance 0.06 0.02 0.02 0.02 0.03
Required minimum distance 1 cm 1 cm 1 cm 1 cm 1 cm

☒

for occupational use

Sensory

Effects

Head

☐

for use by laymen

Health

Effects

☐

☐

n.a

n.a

Trunk

☒

YES

☐

YES

☒

YES

☒

YES

☐

YES

Limb (hand) Limb (thigh)

☐

☒

☐

☐

☒

NO

NO

NO

NO

NO

Distance where all occupational ELV Exposure Indices fall below 0.20 (20%) 1 cm

Distance where all general public ELV Exposure Indices fall below 1.00 (100%) 16 cm

Tested by: Tony Samimi Date tested: 2018 − 01−24

956172332

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2018−01

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 explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train­ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog­nize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

D Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing 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, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn off unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-251958 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the arc

to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

D Do not cut or weld on tire rims or wheels. Tires can explode if heat-

ed. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not 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 welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

OM-251958 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise lev-

el is high.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

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.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use correct procedures and equipment of ade-

quate capacity to lift and support unit.

D If using lift forks to 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 guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

MOVING PARTS can injure.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.

D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

OM-251958 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with electronic equipment

perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.

For more information, go to www.P65Warnings.ca.gov.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is electromagnetically

compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02169 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern­ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: [phone]) (there are 10 OS­HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

OM-251958 Page 4

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.

Contact your local recycling office or your local distributor for further information.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe1 2012−05

Safe37 2017−04

Protect yourself from electric shock by insulating yourself from work and ground.

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Safe2 2017−04

Safe3 2017−04

Safe5 2017−04

Safe6 2017−04

Safe8 2012−05

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Safe10 2012−05

Safe12 2012−05

OM-251958 Page 5

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Do not weld on drums or any closed containers.

Do not remove or paint over (cover) the label.

Disconnect input plug or power before working on machine.

Drive rolls can injure fingers.

Safe14 2012−05

Safe16 2017−04

Safe20 2017−04

Safe30 2012−05

Safe32 2012−05

Welding wire and drive parts are at welding voltage during operation − keep hands and metal 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 instructions and labels before working on machine.

Safe35 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

OM-251958 Page 6

Become trained and read the instructions before working on the
machine or welding.

Safe40 2012−05

31

<10°

Falling unit can cause injury. Do not move or operate unit where it could tip.

2-2. Miscellaneous Symbols And Definitions

Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.

Safe49 2012−05

Safe53 2017−04

A
V

Amperage

Volts

Alternating

Current (AC)

Direct Current

(DC)

Remote

On

Off

Protective Earth

(Ground)

Line Connection

I1eff

U

I

2

X

U

0

IP

Maximum

Effective

Supply Current

Conventional

2

Load Voltage

Rated Welding

Current

Duty Cycle

Percent

Rated No Load

Voltage (OCV)

Degree Of
Protection

Circuit Breaker

Three Phase

Transformer

Rectifier

Hz

t

Voltage Input

Wire Feed

Hertz

Input

Read Operator’s

Manual

Wire Type

Diameter

Spot Weld Time

Wire Burnback

Control

Three Phase

Single Phase

Gas Metal Arc

Welding (GMAW)

U

1

I

1max

Primary Voltage

Rated Maximum

Supply Current

Two-Step Trigger

Operation

Four-Step Trigger

Operation

Gas Input

Gas Output

Gas Type

Wire Run-In

Speed Control

Low Inductance

High Inductance

Preflow Time

Postflow Time

OM-251958 Page 7

SECTION 3 − SPECIFICATIONS

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the 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.

3-2. Specifications

Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-4 and 4-5 for information on con-

.

necting input power.

. This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).

Rated Output

Model

300*

230/400 VAC

50/60 Hz

Wire feed speed range 1.3 mpm to 26 mpm.

Model

380*

230/400 VAC

50/60 Hz

Wire feed speed range 1.3 mpm to 26 mpm.

100% 60% 35%

180 A

23 V

Rated Output

100% 60% 35%

210 A

24.5 V

230 A

25.5 V

270 A

27.5 V

3-3. Duty Cycle And Overheating

300 A

29.0 V

350 A

31.5 V

Max. Open

Circuit

Voltage

43.5 30-300 A 471 x 825 x 1066 88 Net

Max. Open

Circuit

Voltage

43.0 V 30-350 A 471 x 825 x 1066 102.6 Net

Amperage

Range

DC

Amperage

Range

DC

Dimension (mm)

Weight

Dimension (mm) Weight (kg)

Duty Cycle is percentage of 10 min­utes that unit can weld at rated load
without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

(kg)

60% Duty Cycle At 270 Amperes 100% Duty Cycle At 210 Amperes

6 Minutes Welding 4 Minutes Resting

Overheating

OM-251958 Page 8

% DUTY CYCLE

0

Minutes

15

Continuous Welding

A or V

OR

Reduce Duty Cycle

sduty1 5/95

3-4. Volt-Ampere Curves

05

54

04

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.

MigMatic 300

53

03

52

02

DC Volts

51

01

5

0

05

54

04

Max

Min

043023003082062042022002081061041021001080604020

DC Amperes

MigMatic 380

53

03

52

DC Volts

02

51

01

5

0

024004083063043023003082062042022002081061041021001080604020

DC Amperes

OM-251958 Page 9

3-5. Environmental Specifications

A. IP Rating

IP Rating

IP22S

This equipment is designed for indoor use and is not intended to be used or stored outside.

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

−10 to 40°C (14 to 104°F)

*Output is derated at temperatures above 40°C (104°F).

−20 to 55°C (−4 to 131°F)

C. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Z
It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that
the system impedance complies with the impedance restrictions.

at the point of common coupling is less than __mW (or the short−circuit power Ssc is greater than __VA).

max

IP22S 2014−06

Temp_2016-07

Notes

ce-emc 1 2014-07

OM-251958 Page 10

SECTION 4 − INSTALLATION

4-1. Installing Gas Supply

7

5

Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.

1

2

4

Argon Gas Or Mixed Gas

OR

8 9

CO2 Gas

3

1

2

3

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on
rear of welding power source.

7 Flow Adjust

Typical flow rate is between 15-20
liters per minute. Check wire
manufacturer’s recommended
flow rate.

8CO2 Adapter (Customer

Supplied)
9 O-Ring (Customer Supplied)

Install adapter with O-ring between
regulator/flowmeter and CO
cylinder.

2

6

Rear Panel

Ref. 148265-B / Ref. 149827-B / Ref. 158697-A

OM-251958 Page 11

4-2. Installing Wire Spool And Adjusting Hub Tension

Hub Assembly

1

1 Spacers

Use only for 5Kg spool.

15 Kg Wire Spool
Assembly

5 Kg Wire Spool
Assembly

Tools Needed:

OM-251958 Page 12

Ref. D2

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

230 Volts

230 Volts

400 Volts

400 Volts

! Disconnect and lockout/tagout

input power before 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 label − only one is on unit.

2 Jumper Links

Move jumper links to match input volt­age.

Close and secure access door.
Follow established lockout/tagout
procedures to put unit in service.

956142845_5_14_A

OM-251958 Page 13

4-4. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

Elec Serv 2017-01

. Power cord supplied with unit is sized for 230 volt operation. Larger power cord may be required for cable length greater than 3 meters. Consult

national or local regulations.

300

50/60 Hz 3-Phase

Input Voltage (V) 220 400 220 400

Rated Maximum Supply Current I

Maximum Effective Supply Current I

Max Recommended Standard Fuse Rating In Amperes

Min Input Conductor Size In AWG (mm2)

Max Recommended Input Conductor Length In Meters (Feet)

Min Grounding Conductor Size In AWG (mm2)

Reference: 2017 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16) If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

(A) 35.7 20.5 40 23

1max

(A) 21.1 12.1 23.7 13.6

1eff

1

Time-Delay Fuses

Normal Operating Fuses

4

4

2

3

40 25 50 25

50 30 60 30

10 14 10 14

31

(102)

10 14 10 14

39

(127)

380

50/60 Hz 3-Phase

25

(82)

31

(101)

Notes

OM-251958 Page 14

Notes

OM-251958 Page 15

4-5. Connecting 3-Phase Input Power

4

3

6

3

= GND/PE Earth Ground

7

2

L1

5

L2

L3

Tools Needed:

1

OM-251958 Page 16

input2 2012−05 − Ref. 803766-C / Ref. 956142845_5_14_A