Miller Electric Metro 300DX user manual

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1995 Form: OM-156 368B
August
Miller
Effective With Serial No. KF941356
OWNERS
MANUAL
_I_
~_'
CE
Metro 300DX
CC/DC Generator ForSMAW And GTAW
Welding Welding
Maximum
Rated Fuel Sound
Open- Auxiiiary
Welding Amperage
iP
Engine Rating
Circuit Power Power
Rating Capacity
Output Range

DC
Voltage
280 A, 31 VDC,
Single-Phasel
35%
Duty Cycle
RD211
3-Phase,
Ruggenni
98 Lwa 23
72 AMS
7/10 11.8 US
250 30 V kVA/kW, Air-Cooled, gal
A, DC,
20280
32/15 A. 20 L)
60% Two-Cylinder, (44.6
Duty Cycle
(65 Avera

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UI L~ MILLERS TRUE BLUEfi LIMITEDWARRANTY Effective 1, 1995 January with serial number of KD (Equipment a preface or newer) This limited all MILLER warranties and is exclusive with no other or warranties or warranty supersedes previous guarantees expressed Implied. LIMITEDWARRANTY tothetermsandconditions below, MILLER Electric 5. 6 Months Batteries Subject Mt to its retail that new Co., Appleton. Wisconsin, warrants original purchaser g. MILLER sold after the effective date of this limited

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1995 FORM: OM-156 368B EI~RATASHEET December 1, number when Use above FORM extra manuals. ordering in occurred. Thissheet lists to data After thismanualwas refinements printed, equipmentdesign exceptions later in this manual. appearing DIAGRAM CHANGES TO SECTION 6 ELECTRICAL 6-1. Circuit For Generator 2 and 3 this Errata on Sheet) Replace Figure Diagram Welding (see Pages CHANGESTO SECTION 8 PARTS LIST Parts List follows: as Change Dia. Part Replaced ** Quantity No With Description Mkgs. 178 9

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I t OLE OQ~TRU CT 12 13 ~L1 2 lxxx 3 x 4 xx 5 I XQ0$E0 TO 8 TEF~1IJAL r~ ~ ri I 87>A)~ 2ZIV I I 85>B>-~ I I 3o>c>.~L 3tJ>C>~ I I ~ >J~ L~~> 24/4EV I ~, ~ RC5 r~i r~i ~ I~i~&~ ~-~2>~ ~ >~ P108/ROE RO9/PLC~ 85>B>~- ~ >~ ~ ~ I 3O>C>-~ ~5 >~ ~32 >~ ~2 >~ I I ~ ~6 >~ –L~3 >–~~ >~ >~ >~. L~~> ~Z !L~4>–L ~-~8>~~ RO5/RG8 -~9 >~- !4~ >~ -~i~:i -~ >~- ~7 >~ ~2I>~ ~JLLll:~1 ~8 >~L ~3 -~ ~- ~ -~-~Q >- ~49 >~ ~-~4~J ~TO~AL TO LOWER FELD 0.~NT TO RA~ FEW 0~ENT 210 0 0 0 iT-A iT-A ~OVE LEAD 31 TO ~GVE LEAD

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RC7/I&G7 >- >2 >- >3> SD-178 904 OM-156 368B 3 Page

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C 1~ S

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Declaration of Conformity Miller Electric Co. Manufacturers Name: Mfg. W. Street Manufacturers Address: 1635 Spencer WI 54914 USA Appleton, NiETR0 300 DX Declares that the product: (product name) the Directives and Standards: conforms to following Directives Directive: 73/23/EEC Low Voltage Directives: 93/C .93/68/EEC 89/392/EEC,91/368/EEC, 133/04, Machinery Noise Emission Directive: 79/113/EEC Noise level of Generators: 84/535/EEC Welding Standards for Arc Part 1: EN 60974-1: 1990 Safety Weld

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TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS FOR ARC WELDING 1 1-1. 1 Usage Symbol 1-2. Arc Hazards 1 Welding 1-3. Hazards 2 Engine 1-4. Additional Installation, And Maintenance Hazards 3 Operation, 1-5. Standards 3 Principal Safety 1-6. EMF Information 3 SECTION 2 INSTALLATION 4 2-1. Generator 4 Installing Welding 2-2. And Dimensions, 4 Weights, Operating Angles 2-3. Fuel 5 Consumption 2-4. Label 5 Rating 2-5. And Muffler Connecting Battery Pipe 6 Installing 2-6. Prestart Checks 7 Engine T

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- SECTION 1 SAFETY PRECAUTIONS FOR ARC WELDING 4/95 sately_roml 1-1. Symbol Usage Marks a Means Watch Out! There are hazards with this A special safety Warning! possible message. The in a hazards are shown the procedure! possible adjoining symbols. ~ Means NOTE; not related. safety Out! ELECTRIC This of means Watch SHOCK, MOVING group symbols Warning! possible 1 PARTS, andHOT PARTS hazards. Consult and related instructions below for symbols necessary ~1!~~d~ actions avoid the hazards. to 1-2.

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4. Never torch a CYLINDERS can if drape a welding over cylinder. explode damaged. gas 5. Never allow a electrode to touch contain under welding any cylinder. Shielding cylinders high gas gas If a can damaged, cylinder explode. 6. pressure. Never weld on a explosion will result. pressurized cylinder Since are ofthe cylinders normally part welding gas 7. Use and only correct shielding regulators, hoses, gas cylinders, be to treat them sure carefully. process, for the maintainthem and fittings de

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1-4. Additional And Maintenance Hazards Installation, Operation, a WARNING MOVING PARTS can cause READ INSTRUCTIONS. injury. Before of 1. remove working generator, spark plugs 1. Use MILLER only genuine replacement parts. or to from back or injectors keep engine kicking 2. Reinstall and bleed air from fuel injectors system starting. to manual. according engine Block so that it will not turn while flywheel working on components. generator DO NOT LET ENGINE EXHAUSTSPARKS FLYING PIECES OF METAL or

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SECTION 2-INSTALLATION 2-1. Generator Installing Welding 2-2. Dimensions, Weights;And Operating Angles Dimensions 41 in Do not exceed Height (1041 mm) A while operating angles or will occur. running engine damage Width 30 in (762 mm) 54-1/2 in Depth (1384 mm) A 29 in (737 mm) 25 B 36-3/4 in (933 mm) 25 C 150 9/l6in(l4mm)Dia. Weight Net 960 lb (435 kg) C 4 Holes 1070 lb Ship (485 kg) Sr-158 938 4 OM-156 368 Page

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2-3. Fuel Consumption Q. ~ -J 1,04 4.73 1.25 I I ITT IILII 3.78 0.84 1.00 - A POW~ ,~,, ~ 2.84 063 0.75 ~ 7tt+- ; ~ ~ cc ~ ~~ 1.89 0.42 0.50 y__ ~ 0.95 0.21 025 ~OLEJ I I I I II I 0.00 0.00 0.00 I I I I I I I I I I I I I o 25 ~) 75 1~ 125 150 175 20] 225 2~Q 275 30) DC WELD AWERES AT 630% DUTY CYCLE I I I I I I I I I I ~I I I 4 O I 2 3 5 6 7 8 9 13 11 12 SA-175 807 POWER KVA AT DUTY 130% CYCLE 2-4. Label Rating label shown Rating includes op tional48 volt dinse in receptacle EN 60974-1 forma

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2-5. And Muffler Connecting Battery Installing Pipe OM-156 368 6 Page

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2-6. Prestart Checks Engine Check all fluids must daily. Engine cold and be on a level surface. if oil is low. Engine stops pressure first A Heavy loading during 50 hours will en damage load less than gine. Keep 225A or7kVA (weld) (power) for first 50 hours. Ref. ST-159 219-D 2-7. Weld Terminals And Cable Sizes Output Selecting Total Cable in Weld Circuit Not (Copper) Length Exceeding r 150ft 200ft 250ft 300ft 350ft 400ft 100 ft Or Less (30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) 1060% 6

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2-8. Remote 14 RC1 Information Receptacle Sockete Socket Information REMOTE 14 A 24 volts ac with to socket G. respect B Contact closure to A 24 volts control completes ac contactor circuit. 24 voltsAC G Circuitcommon ~for circuit. C +10 volts dc to remote control with to socket D. output respect D Remote control circuit common. E 0 to volts dc command from remote control with +10 input signal A socket D. respect to K Chassis common. ST-Isa 934-B *The sockets used. remaining are not SECTION 3-OP

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3-2. Front Panel Controls 8 9 1 2 7 idle Lock Switch Using 2100 rpm (No Load) 3200 (Load) rpm 3200 rpm Ret. ST-175 920-A first 50 hours To Start: Idle Lock switch Idle in and reduce the chance of the Heavy loading during move to posi arc starts, A will load less tion and Control switch to Start electrode in the Set at damage engine. Keep Engine posi freezing puddle. than 225A or 7 kVA tion. Release. Control. switch .when minimum for (weld) (power) Engine Tig welding. Do crank while for first 50

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And 3-3. Duty Cycle Overheating 4~fl is of 10 Duty Cycle percentage weld minutes that unit can at rated load without overheating. can A Exceeding duty cycle unit and void war damage ranty. : ~. ; . ~-. ~- 2cXJ 3 40 50 8) 70 80 8) fi) Z DUTY CYCLE At 280 35% Cycle Duty Amperes 60% At 250 Duty Cycle Amperes 3-1/2 6-1/2 6 Minutes 4 Minutes Minutes Minutes Welding Resting Welding Resting 100% At 225 Duty Cycle Amperes Continuous 5/95/SB-176 134 dutyl Welding 3-4. Remote Control Amperage Weld termin

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SECTION 4-OPERATING AUXILIARY EQUIPMENT 4-1. Power Auxiliary Receptacles 6 4 5 35OHz 1-~50Hz 380V 220V Ref. SC-175 913 is will GFCI1 fault for output exceeded, auxiliaryequipment provides ground protection available at (IJ~ Auxiliary ac power recep not run and RC3. stop or properly. RCI, RC2, tacles decreases weld in as amperage 4 Circuit Breakers CB1, CB2, And CB3 creases. V A 7 48 50 AC Dinse RC4 Receptacles CB1 CB3 RC1 from thru overload. If protect And RC5 (Optional) 1 380 V 15 AAC RC1 Rec

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SECTION 5- MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance before A Stop engine maintaining. See also Manual and Mainte OJ~ Engine Recycle engine nance LabeL Se,vice more often engine fluids. conditions. severe .during 8 Hours 50 Hours 100 Hours fi Clean And Tighten Connections. Battery See Section 2-5 P 200 Hours 300 Hours 500 Hours fi Or Repair Repiace Cracked Cabies 4 Blow Out Or Vacuum inside. Service, During Heavy Clean Monthly OM-156 368 12 Page