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OM-259 177 743E
May 1998
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
CP-202, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols for Installation, Operation, and
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body. fields. However, after examining more than 500 studies spanning 17 years of resea
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SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_Fre 4/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN Identifie un message de sécurité particulier. MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous a
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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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 Model W Welding elding V Voltage oltage 200 220 230 380 400 440 460 520 575 Output Range KVA KW V V V V V V V V V DC 200 A @ 28 21.9 19.1 19 12 10.5 9.5 9.5 8.8 7.6 7.2 Volts DC, 100% 200Amp 14−39 −− 3* 2.8* 2.7 1.9* 1.6* 1.5* 1.4* 1.1* 0.97* 0.68* Duty Cycle 250 A @ 35 34.5 30 15 11.9 11.2 250 Amp Volts DC, 100% 14−44 −− −− −− −− −− −− 1.7* 1.4* 0.7*
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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. 200 And 300 Ampere Models va_curve1 4/95 − SA-180 902 / SA-180 901-A OM-259 Page 10
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2-4. Dimensions And Weights C C Dimensions Dimensions D D Height 27-1/4 in (692 mm) E 4 4 Holes Holes Width 22-1/4 in (565 mm) Depth 28-1/4 in (717 mm) A 27-1/2 in (698 mm) B 3/4 in (19 mm) A A C 21 in (533 mm) D 1-3/16 in (30 mm) E 7/16 in (11 mm) Dia Weight 320 lb (145 kg) B ST-801 530 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 uni
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2-6. Slope Selection (250 Ampere Model) 1 Slope Connection Label 2 Tapped Reactor AC-Z And Slope Coils Tapped reactor AC-Z is factory con- nected to slope tap 8 which is suit- able for most GMAW applications. AC-Z controls the inductance applied to the weld current. To increase inductance and wet out the weld puddle, connect to a higher tap number. To stiffen the weld 4 puddle, connect to a lower tap num- ber. 7 3 Leads 70, 71 and 72 With Pressure Connectors Slide pressure connectors onto the sa
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2-7. Inductance Selection (200 And 300 Ampere Models) 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 current. To in- crease inductance and wet out the weld puddle, connect to stabilizer Z ending. To change inductance proceed as follows: 2 Lead 25 3 Stabilizer Z Tap 4 Stabilizer Z Ending 5 Lead 26 To increase inductance, connect lead 26 to stabilizer ending and secure. Reins
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2-8. 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 shiel
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2-10. Connecting To 115 Volts AC Duplex Receptacle 1 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and remote 14 receptacle RC8. 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts ac portion of RC8 and RC9 from overload. 3 CB2 protects 24 volts ac portion of RC8 from overload. 2 Press button to reset breaker. 1 Ref. ST-801 380-B 2-11. Electrical Service Guide 60 Hertz Models 250 Amp Model 300 Amp Model Input Voltage 200 230 460 200 230 460 575 Input Amperes At Rated Ou
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2-12. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 1 Jumper Link Label Check label − only one is on unit. 2 Jumper Link Move jumper links to match input 2 voltage, and label on unit. 3 Input And Grounding 200 VOLTS 230 VOLTS 460 VOLTS Conductors See Section 2-11. L1 L2 L3 L1 L2 L3 L1 L2 L3 4 Line Disconnect Device S-072 135-B See Section 2-11. 220 VOLTS 400 VOLTS 440 VOLTS Close access door. L1 L2 L3 L1 L2 L3 L1 L2 L3 S-177 581 380 VOLTS 520 VOLTS L1 L2
