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OM-259 177 743P
June 2003
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
CP-302 and
CP-252TS
Visit our website at
www.MillerWelds.com
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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 bu
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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 . . . . .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_7/02 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- (phone: 305-443-9353, website: www.aws.org). ternational.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection, ting of Conta
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SECTION 1 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som _nd_fre 7/02 1-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux Identifie un message de sécurité particulier. PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symbole
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LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation. tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien ventiler les espaces confinés ou porter un
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1-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. Ne pas placer l’appareil sur une surface inflam- Se tenir à l’écart des organes mobiles comme les mable, ni au −dessus ou à proximité d’elle. ventilateurs. Maintenir fermés et bien fixés les portes, Ne pas installer l’appareil à proximité de produits inflammables. panneaux, recouvrements et dispositifs de
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1-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463 −6727 ou à Toronto : (416) 747 −4044, site Web : www.csa−interna- (téléphone : (305) 443 −9353, site Web : www.aws.org). tional.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protect
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SECTION 2 − INSTALLATION 2-1. Specifications Open- Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Rated Rated Circuit Circuit Model Welding Voltage 200 220 230 380 400 440 460 520 575 Output Range KVA KW V V V V V V V V V DC 250 A @ 35 34.5 30 15 11.9 11.2 Volts DC, 100% 250 Amp 14 −44 −− −− −− −− −− −− 1.7* 1.4* 0.7* 0.57* 0.42* Duty Cycle 300 A @ 32 38 34.5 33 20 19 17.3 16.5 14.6 13.0 13.1 12.3 300 Amp Volts DC, 100% 14 −44 3* 2.8* 2.7* 1.9* 1.6* 1.5* 1.4* 1.1* 0.7* 0.97* 0.68*
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2-3. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. A. 250 Ampere Models B. 300 Ampere Models CP302 MAX CP302 MIN va_curve1 4/95 − SA-180 902 / SA-180 901-B OM-259 Page 10
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2-4. Dimensions And Weights Dimensions Dimensions A A 30 in (762 mm) Including lift eye B 23 in (584 mm) 31 in (787 mm) Including strain C relief C B D 27-1/2 in (699 mm) F E 3/4 in (19 mm) G H 4 Holes F 21-1/8 in (537 mm) G 1-1/8 in (29 mm) D H 7/16 in (11 mm) Dia Weight 320 lb (145 kg) Front E 800 453-A / 801 530 OM-259 Page 11
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2-5. Selecting A Location 1 Rating Label Use rating label to determine input power needs. Label located under front access door. Tipping Movement 2 Line Disconnect Device Do not move or operate unit Locate unit near correct input where it could tip. power supply. Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Location And Airflow 2 1 18 in (460 mm) 18 in Ref. ST-801 378-B (460 mm) 2-6. Typical MIG Process Connectio
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2-7. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as Constant close to the weld as possible. Current (CC) Voltage sensing wire feeders are Or Constant used with constant current (CC) or Voltage (CV) constant voltage (CV) power Power Source sources (14 pin receptacle not re- quired). If using a CC welding power source without a weld output con
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2-8. Slope Selection (250 Ampere Model) Disconnect and lockout/tag- out input power before re- moving side panel. Lockout/tagging procedures con- sist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. 1 Slope Connection Label 2 Tapped Reactor AC-Z And 4 Slope Coils 7 Tapped reactor AC-Z is factory con- nected to slope tap 8 which is suit- able for most GMAW applications. AC-Z contr
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2-9. Inductance Selection (300 Ampere Models) Disconnect and lockout/tag- out input power before re- moving side panel. Lockout/tagging procedures con- sist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. 1 Stabilizer Z Tapped stabilizer Z is factory connected to the stabilizer tap which suits most GMAW applications. Stabilizer Z controls the inductance applied to the weld curren
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2-10. Weld Output Terminals And Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shie
