Miller Electric PRO 300 User Manual

Page 1
Standard features include: Stick, Lift-Arc™TIG, Flux Cored and MIG.
Other features include digital preset weld meters, output contactor control, and automatic idle.
Processes
Stick (SMAW) MIG (GMAW) Flux Cored (FCAW) DC TIG (GTAW) Air Carbon Arc (CAC-A)
Rated: 3/16 in (4.8 mm) carbons, Capable: 1/4 in (6.4 mm) carbons
Air Plasma Cutting and Gouging with
optional Spectrum models
Industrial Applications
Pipe Welding Structural Steelwork Fabrication Maintenance Repair
Quick Specs
PRO 300
Engine-Driven Welder/
AC Generator
Issued May 2008 • Index No. ED/5.21
Auto Remote Sense (ARS) detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/panel switch.
Simple-to-set controls require no elaborate procedure — just select process and weld!
Tailored Arc Control (DIG) allows the arc characteristics to be changed for specific applications and electrodes. Smooth running 7018 or stiffer, more penetrating 6010 electrodes.
The Power of Blue®.
Welder/generator is warranted by Miller for 3 years, parts and labor.
Engine is warranted 3 years by engine manufacturer.
Miller Electric Mfg. Co.
An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125
Output Range DC Stick 40 – 410 A
DC TIG 20 – 410 A FCAW/MIG 14 – 40 V
Generator Output Rated at 104˚ F (40˚ C)
12,000 Watts Peak 10,000 Watts Continuous
Quiet operation: Improves work site communication.
CATERPILLAR C1.5,
21.7 HP @ 1800 RPM industrial engine
Heavy-Duty Low-Speed Industrial Engine Choices!
Deutz D2008 L04,
24.3 HP @ 1800 RPM industrial engine
Designed to operate over 10,000 hours before the first basic overhaul. Backed by worldwide support and service.
Thermal overload protection
prevents machine damage if the duty cycle is exceeded or airflow is blocked.
Optional Stainless Steel Appearance Package provides
additional exterior protection to withstand corrosive environments.
Improved!
Superior Arc
Performance!
Accu-Rated
– Not Inflated
Generator Power
The Professional Welder’s Choice — designed with the
professional in mind, the PRO 300 is the best for ease of use, reliability and fuel economy.
Superior arc performance
• Four preset DIG settings (Stick)
• Hot Start
(Stick)
• Lift-Arc™TIG with Auto-Stop
and Crater-out
• MIG/FCAW arc performance
Meter maintenance displays.
• Hour meter function
• Oil change interval
• High coolant temperature and low oil pressure shutdowns
• Low fuel shutdown — engine shuts downs before system runs out of fuel, making restarts easy.
The Vault — ultimate control board reliability. See page 4.
Page 2
Performance Data
2
Specifications (Subject to change without notice.)
Engine Specifications (Engines warranted separately by the engine manufacturer.)
Engine Brand
CATERPILLAR C1.5
Deutz D2008 L04
Features
EPA Tier III indirect-injected liquid-cooled engine. Right side service access with intervals of 250 hrs for oil and filters.
EPA Tier IVi indirect-injected liquid-cooled engine. Right side service access with intervals of 250 hrs for oil and filters.
HP
21.7
24.3
Type
3-cylinder, industrial liquid-cooled, diesel
4-cylinder, industrial liquid-cooled, diesel
Engine Speeds
1850 RPM weld (1500 RPM idle)
1800 RPM weld (1500 RPM idle)
Fuel Capacity
11.5 gal (43.5 L)
Oil Capacity
6 qt (5.7 L)
Coolant Capacity
6 qt (5.7 L)
Automatic Engine Shutdown
Low Oil Pressure, High Coolant Temperature, Low Fuel Level
SIMULTANEOUS WELDING AND POWER
225 175 125 75 25
Weld Amperes
Total Power Available (Watts)
120 V 240 V
3000 5000 5900 7300 10,000
25
41.6
49.2
60.8
83.5
12.5
20.8
24.6
30.4
41.7
STICK MODE V/A CURVE – MAX DIG
DC VOLTS
DC AMPERES
0 100 200 300 400 500
600
100
90 80 70
60 50 40 30 20 10
0
MIN
MAX
300
MIG MODE V/A CURVE
0 100 200 300 400 500 600
100
80 60 40 20
0
DC VOLTS
DC AMPERES
MIN
MAX
FUEL CONSUMPTION CURVE
IDLE
DC WELD AMPERES
AT 100% DUTY CYCLE
U.S. GAL/HR.
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
0
50 100 150 200 250 300 350 400
GENERATOR POWER CURVE
0 40 80 120 160
020406080
AC AMPERES IN 120 V MODE
AC AMPERES IN 240 V MODE
300
250
200
150
100
50
0
150
125
100
75
50
25
0
AC VOLTS
DC TIG MODE V/A CURVE
DC VOLTS
DC AMPERES
0 100 200 300 400 500
100
90 80 70
60 50 40 30 20 10
0
MIN
MAX
300
Weld Mode
CC/DC
CV/DC
Weld Output Range
20 – 410 A
14 – 40 V
Weld Output Rated at 104˚ F (40˚ C)
400 A, 20 VDC, 30% Duty Cycle 300 A, 32 VDC, 60% Duty Cycle
Max. Open­Circuit Voltage
65
Generator Power Output Rated at 104˚ F (40˚ C)
12,000 Watts Peak 10,000 Watts Continuous Single-phase, 120/240 VAC, 83/42 A 60 Hz
Dimensions
H: 32 in (813 mm) W: 26-1/4 in (667 mm) D: 56 in (1422 mm)
Net Weight (without fuel)*
CAT:
Net: 1128 lb (512 kg) Ship: 1150 lb (522 kg)
Deutz:
Net: 1208 lb (548 kg) Ship: 1230 lb (558 kg)
Sound Levels at Rated Output, 7 m (23 ft)
CAT:
71 dB (96 Lwa)
Deutz:
73 dB (98 Lwa)
CSA approved. Meets NEMA and IEC output ratings. *Additional 82 lb (37 kg) when fuel tank is full.
Page 3
3
Function Guide
1. Self-calibrating digital weld meters with meter maintenance displays.
2. Four Preset DIG Settings offer the best
arc characteristics for different electrodes and joint designs. The amount of DIG determines how much amperage (heat) varies with Stick arc length. The combined Process switch along with preset DIG settings make the PRO 300 easy to set without the complication of multiple switches.
3. Hot Start
provides positive Stick electrode starts making it easy to start all types of electrodes and it also works great for bead tie-ins.
4. Great MIG/FCAW Performance and Arc Starts make the PRO 300’s arc best in its
class. Easy to run all wires from .023 in solid wires to large diameter 5/64 in flux cored wires.
5. Lift-Arc
TIG with Auto-Stop™and
Crater-out (patents pending)
6. Standard 14-Pin Receptacle for simple
connection of remote controls and wire feeders. It features Auto Remote Sense
which automatically switches from Panel to Remote Amperage/Voltage (A/V) control with remote connected. Eliminates confusion of the Panel/Remote A/V switch.
7. Weatherproof Lexan
®
Nameplate is super
durable and resists cracking and fading. Color coding is for ease of operation.
8. Fuel Gauge displays engine hours and oil change interval information.
Low Fuel Shutdown shuts engine off prior to running out of fuel to prevent loss of fuel in the system, and make restarts easy. Display will read noFUEL. Turn the machine off, add fuel, and restart.
9. Glow Plugs assist in cold weather starting.
10. Engine Control Switch is used to start the
engine and then select between Auto Idle and High Speed Lock.
11. Amperage/Voltage Adjust Control
12. 120 VAC and 240 VAC Receptacles with Circuit Breakers (optional 120 VAC GFCI
receptacles available).
Note: For matching plug, order #119 172.
13. Weld Output Terminals
• Eliminates need for a remote control
• Maintains shielding gas coverage
• Eliminates tungsten and workpiece contamination
• Eliminates unwanted arc strikes outside the weld area
• Reduces or eliminates sticking
• Reduces or eliminates electrode/ work contamination
• Low open-circuit voltage (approximately 10 volts)
• Maintains shielding gas coverage
• Eliminates tungsten and workpiece contamination
• Crater-out time allows for addition of filler
• Eliminates unwanted arc strikes outside the weld area
1
8
2 3
4
9
10
11
5
12
6
7
13
Arc
Lift at any angleTouch or scratch
Shielding
gas
ARC START with Lift-Arc
Shielding
gas
Workpiece
ARC END with Auto-Stop
While welding
Lift up
gas
until arc
ends
Shielding
Arc
Workpiece
ARC END with Crater-out
While welding
Shielding
Arc
Workpiece
To start Crater-out, press
momentary contact switch
gas
For Auto-Stop, lift up to terminate arc
Arc ends
without
flare
Welding
current
ramps
down
maintain gas
Maintain shielding
coverage
Move back
down to
coverage
gas
Page 4
4
Rigorous Testing for Tough, Real-World Conditions
To prove our machines go to the limit, Miller industrial engine drives are put to the test in very extreme environmental conditions.
Airborne Dust and Sand
Critical components are exposed to abusive airborne particles in a special testing chamber for weeks, helping make sure they’ll operate while facing extreme levels of dirt, dust or sand on the job site.
Humidity and Corrosion
Inside Miller’s Houston testing room, critical components are subjected to extended moisture and corrosive salt exposure to ensure they’ll run even when exposed to humid climates, corrosive coastal environments, and driving rain.
Temperature Extremes — Miller’s industrial engine drives
are tested to ensure performance in scorching heat. All Miller engine driven machines are weld rated at 104˚ F, but actual tests are conducted up to 122˚ F to assure peak performance.
Jobsite/Over-the-Road Abuse — Miller industrial engine
drives are shaken for hours on transportation bed simulators, subjected to severe vibration, and test-dropped and jerked to ensure they’ll withstand the stresses that can shut down competitive machines.
Continuous Operation — Miller’s industrial engine drives run
day and night, in all weather conditions, to assure they’ll perform without interruption in the field.
Superior Circuit Board Design
Miller’s critical circuit boards are engineered to carry
low power
and
low heat
to reduce thermal stress and minimize expansion
and contraction. In contrast, our competitor’s boards carry
high
power
and
high heat
, making them more vulnerable to failure.
What Makes Miller Industrial Engine Drives So ?
“The Vault” Makes Upgrading to Miller CC/CV Units Worry-Free
Concerns with circuit board reliability have resulted in some operators steering clear of CC/CV welder/generators — even though they offer a superior arc and multiple welding processes. Miller’s circuit board reliability isn’t a concern since all PRO 300 and Big Blue multiprocess industrial engine drives feature the Vault.
Created out of two aluminum halves sealed with silicone, as well as watertight harness connections, the Vault provides a clean circuit board environment, protecting the electronics — and controlling output — in heavy industrial applications. No other competitor protects their electronics with a sealed vault, leaving critical circuit boards exposed to harsh elements that can disrupt the machine’s electronics, and therefore, its operation.
“The PRO 300 worked year ’round and never caused any problems. We were amazed at the cold-weather starting. A machine that doesn’t run means we have to work overtime… secondly, you don’t want to have a crew standing around at $200 an hour while someone tries to start the machine.”
Edward McNaughton, Nordcap Steel Docks
Why Industrial Engine Drive Customers Choose Miller
The ultimate test of Miller’s reliability is how it performs in the field. The quote on the left provide a glimpse of how Miller industrial engine drives perform for customers. Read the full stories, and many others demonstrating Miller’s superior reliability, at MillerWelds.com.
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5
Adapter Cord, Full KVA #300 158 Field
NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to common Millermatic
®
and Spectrum®240 V plug.
Full KVA Plug Kit #119 172 Field
120/240 VAC, 50 amp plug (NEMA 14-50P) to fit full KVA receptacle.
Cold Weather Starting Aid #195 056 Field 120 V block heater.
Note: All models come standard with preheaters (glow plugs).
Spark Arrestor (Muffler) Kit #195 291 Field Prevents particles from leaving the muffler that could potentially start a fire. Mandatory when operating on California grasslands, brush, or forest-covered land, and all national forests. For other areas, check your state and local laws. Meets U.S. Forest Service Standard 5100-1B.
FA-1D Lockable Flame Arrestor Fuel Cap #043 947
Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank.
Protective Cover #195 301 Field Blue water-resistant cover with Miller logo resists stains and mildew, and protects the finish of your welder.
Stick (SMAW) Welding
Weld Leads #173 851 2/0, 350 A, 100% duty cycle,
50 ft stinger, 50 ft work cable
#043 952 2/0, 300 A, 100% duty cycle,
100 ft stinger, 50 ft work cable
Plasma Cutting
Spectrum®375 X-TREME™#907 303 Spectrum®375 X-TREME™with X-CASE
#907 339 (not shown)
See Lit. Index No. PC/9.2.
Spectrum
®
625 #907 058
See Lit. Index No. PC/9.5.
Spectrum 2050 #903 777-01-2
See Lit. Index No. PC/7.0.
MIG (GMAW) or Flux Cored (FCAW)
Millermatic
®
Passport®Plus #907 401
Portable, all-in-one MIG package features ultimate arc performance, self-
contained gas bottle, and flexibility to plug into 115 or 230 V power with Miller exclusive Multi-Voltage Plug. See Lit. Index No. DC/12.53.
SuitCase
X-TREME™8VS Wire Feeder #300 093 SuitCase
X-TREME™12VS Wire Feeder #195 500
Lightweight, voltage-sensing wire feeders include secondary contactor and gas valve. Require drive roll kit. See Lit. Index No. M/6.41.
SuitCase
8RC Wire Feeder #194 938 SuitCase™12RC Wire Feeder #194 940
Lightweight and flexible enough to run a variety of wires up to .062 in diameter. Comes standard with remote voltage control. See Lit. Index No. M/6.5.
MIG (GMAW)/Flux Cored (FCAW) Guns
Miller produces a com plete line of dependable MIG guns. See Lit. Index Nos. AY/15.0, AY/16.0 and AY/17.0.
Spoolmatic
®
30A Spool Gun #130 831
Air-cooled, 200-amp, 1-lb spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
XR
Wire Feeders and Guns
Push-pull system designed to handle difficult-to-feed soft alloy wires such as aluminum. See Lit. Index No. M/1.7, M/1.71, and M/1.73.
TIG (GTAW) Welding
HF-251 Series #042 388
HF-251D-1, 115 VAC High-frequency arc starter and stabilizer. See Accessory Lit. Index No. AY/5.0.
Multiple Operator Welding
The XMT 304, CST 280 and Dynasty 200 power sources can be run off the machine’s generator to provide two arcs with only one engine. There is no arc interaction under 180 amps.
XMT®304 #903 471 and #903 471-01-1 only
See Lit. Index No. DC/18.8.
CST
280 #907 244, #907 244-01-1 #907 251, #907 251-01-1
See Lit. Index No. DC/29.55.
Dynasty
®
200 Series #907 099 #907 099-01-1
See Lit. Index No. AY/4.8.
Genuine Miller Accessories
Female Receptacle
Page 6
6
Genuine Miller Accessories
(continued)
Mid-Frame Trailer #195 481
1500 lb (680 kg) capacity highway trailer. Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Comes with jack stand, and safety chain (order hitch separately).
Ball Hitch, 2 in #195 493 Lunette Eye 2-1/2 in (64 mm) #043 824 Fender Kit #195 482 Light Kit #195 483
Requires fender kit.
Cable Tree #195 023
Provides an area to conveniently wrap weld cables and extension cords.
HWY-224 Trailer #043 805 For highway use.
OFR-224 Trailer #043 802 For off-road use.
A 2650 lb (1202 kg) capacity trailer. Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, 2 in (50 mm) ball hitch.
HWY-224 also includes fenders
and lights.
Note: Trailer is shipped unassembled.
Cable Tree #043 826
Provides an area to conveniently wrap weld cables and extension cords.
Lunette Eye 2-1/2 in (64 mm) #043 824
Mounting Specifications
A. 27-3/4 in (705 mm) B. 26-1/4 in (667 mm) C. 52 in (1321 mm) D. 2 in (51 mm) E. 56 in (1422 mm) F. 9/16 in (14 mm) dia.
Trailers and Hitches
(Note: Trailers are shipped unassembled.)
Shown with ball hitch, fenders and lights.
Height: 32 in (813 mm) Width: 26-1/4 in (667 mm) Depth: 56 in (1422 mm)
Specifications (Subject to change without notice.)
Gross Vehicle Weight Rating
1666 lb (755 kg)
2960 lb (1343 kg)
Gross Axle Weight Rating
1500 lb (680 kg)
3500 lb (1588 kg)
Height of Bed
18-1/2 in (470 mm)
18-1/2 in (470 mm)
Road Clearance
6-1/2 in (165 mm)
7-1/2 in (191 mm
Net Weight
242 lb (110 kg)
355 lb (161 kg)
Track (Center to center of tires)
45 in (1143 mm)
52 in (1321 mm
Standard Tires (Standard rating or P-size rating)
B78-13
B78-13
Dimensions
Length: 98 in (2489 mm) Width: 52 in (1321 mm)*
Length: 122-1/2 in (3112 mm) Width: HWY– 61 in (1549 mm)*
OFR–58-1/2 in (1486 mm)
*
Width at outside of fenders.
Model Mid-Frame
HWY-224 OFR-224
Net Payload
1424 lb (645 kg)
2650 lb (1202 kg)
Remote Controls
RHC-14 Hand Control #129 340
Miniature hand control for remote current and contactor
control. Dimensions: 4 x 4 x 3-1/4 in (102 x 102 x 82 mm). Includes 20 ft (6 m) cord and 14-pin plug.
RFCS-14 HD Foot Control #194 744
Heavy-duty foot current and contactor control. Includes 20 ft (6 m) cord and 14-pin plug.
RMLS-14 #129 337 14-pin plug Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and back for momen ­tary contact. Includes 20 ft (6 m) cord.
RMS-14 On/Off Control #187 208
Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5 ft (8 m) cord and 14-pin plug.
RCC-14 Remote Contactor and
Current Control #151 086 14-pin plug
Rotary-motion fingertip control fastens to TIG torch using two Velcro
®
straps.
Includes 28 ft (8.5 m) control cord.
PRHC-14 Hand Control #195 511
Complete current or voltage control brings 120 volts GFCI power to
work area in a single cord. Housed in a durable light aluminum case and includes 125 ft (38 m) cord with plugs.
Extension Cords for 14-Pin Remote Controls or 24 VAC Wire Feeders #122 973 25 ft (7.6 m) #122 974 50 ft (15.2 m) #122 975 75 ft (23 m)
4 holes
F
B
Front Panel
A
C D E
Page 7
7
Plasma Basic Equipment
Spectrum®375 X-TREME™#907 303 Spectrum
®
375 X-TREME™with X-CASE
#907 339 Spectrum®625 #907 058 Spectrum
®
2050 #903 777-01-2
Stick (SMAW) Basic Equipment
Flux-Cored (FCAW) Basic Equipment
SuitCase™X-TREME™ 8VS #300 093 SuitCase™X-TREME™12VS #195 500
MIG (GMAW) Basic Equipment
SuitCase™8RC #194 938 SuitCase™12RC #194 940
Aluminum MIG (GMAW) Basic Equipment
Spoolmatic®30A #130 831 WC-24 #137 549
TIG (GTAW) Basic Equipment
Dynasty®200 Series HF-251D-1 #042 388* *TIG power cable adapter required
Typical Installations
Stick Electrode
Work
14-Pin
14-Pin
14-Pin
X-TREME 8VS/
X-TREME 12VS
Feeder
SuitCase
8RC/12RC
WC-24
HF-251D-1
Flux Cored Gun
Work
MIG Gun
Work
Aluminum MIG with
Spoolmatic 30A Gun
Work
TIG
Torch
Work
Cutting Torch
Spectrum
Work
Page 8
Litho in USA
Distributed by:
Equipment and Options Stock No. Description Qty. Price
PRO 300 CC/CV #907 144 CAT CC/CV
#907 144-01-1 CAT CC/CV, 120 V Block Heater #907 144-02-1 CAT CC/CV, 120 V Block Heater, Stainless Steel Package
PRO 300 D CC/CV #907 399 Deutz CC/CV
#907 399-01-1 Deutz CC/CV, 120 V Block Heater #907 399-02-1 Deutz CC/CV, 120 V Block Heater, Stainless Steel Package
Accessories
Cold Weather Starting Aid #195 056 Field, 120 V block heater Spark Arrestor (Muffler) Kit #195 291 Field FA-1D Lockable Flame Arrestor Fuel Cap #043 947 Field Adapter Cord, Full KVA #300 158 Field Full KVA Plug #119 172 Field Protective Cover #195 301 Field
Remote Controls and Switches See page 6
Multiple Operator Welding
XMT
®
304 CC/CV #903 471 See Lit Index No. DC/18.8
#903 471-01-1
CST
280 CC/DC #907 244 220-230/460–575 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55
#907 244-01-1 220-230/460– 575 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55 #907 251 208-230/400 –460 VAC w/Dinse-style connectors. See Lit Index No. DC/29.55 #907 251-01-1 208-230/400– 460 VAC w/Tweco-style connectors. See Lit Index No. DC/29.55
Dynasty®200 SD #907 099 Basic controls for AC/DC TIG/Stick, 120– 460 VAC. See Lit Index No. AY/4.8 Dynasty®200 DX #907 099-01-1 Full feature controls for AC/DC TIG/Stick, 120–460 VAC. See Lit Index No. AY/4.8
Plasma Cutting
Spectrum®375 X-TREME™(only) #907 303 See Lit Index No. PC/9.2 Spectrum®375 X-TREME™with X-CASE™#907 339 See Lit Index No. PC/9.2 Spectrum®625 #907 058 See Lit Index No. PC/9.5 Spectrum®2050 #903 777-01-2 See Lit Index No. PC/7.0
MIG/Flux Cored Welding
Millermatic®Passport®Plus #907 401 Includes gas bottle and MVP. See Lit. Index No. DC/12.53 SuitCase™X-TREME™8VS #300 093 See Lit Index No. M/6.41 SuitCase™X-TREME™12VS #195 500 See Lit Index No. M/6.41 SuitCase™8RC #194 938 See Lit Index No. M/6.5 SuitCase™12RC #194 940 See Lit Index No. M/6.5 MIG (GMAW) and Flux Cored (FCAW) Guns See Lit Index Nos. AY/15.0, AY/16.0 and AY/17.0 Spoolmatic®30A Spool Gun #130 831 Requires WC-24 Control. See Lit. Index No. M/1.73 WC-24 Control #137 549 See Lit. Index No. M/1.5 XR™Wire Feeder Control and Guns See Lit. Index No. M/1.7, M/1.71, and M/1.73
TIG Welding HF-251 Series #042 388 115 VAC. See Lit. Index No. AY/5.0
Trailers and Hitches
Mid-Frame Trailer #195 481 Trailer with jack stand and safety chain. Order hitch separately Ball Hitch, 2 in #195 493 Lunette Eye #043 824 Fender Kit #195 482 Light Kit #195 483 Requires fender kit Cable Tree #195 023 Trailer-mounted cable holder HWY-224 Trailer #043 805 Trailer with lights, fenders and 2 in ball hitch. For highway use OFR-224 Trailer #043 802 Trailer with 2 in ball hitch. For off-road use Lunette Eye, 2-1/2 in #043 824 For HWY-224 or OFR-224 Cable Tree #043 826 Trailer-mounted cable holder for HWY-224 or OFR-224
Date: Total Quoted Price:
Ordering Information
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