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Summary of Contents for Miller Electric CP-202
- Page 1 Visit our website at www.MillerWelds.com CP-202, CP-302, and CP-252TS OM-259 177 743E May 1998 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source...
- Page 2 ISO 9001 Quality service information for your particular model System Standard. are also provided. 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.
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Page 3: Table Of Contents
SECTION 1 − SAFETY PRECAUTIONS 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols for Installation, Operation, and Maintenance 1-4. Principal Safety Standards 1-5. EMF Information The following terms are used interchangeably SECTION 1 − CONSIGNES DE SECURITE throughout this manual: 1-1. -
Page 5: Section 1 − Safety Precautions
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2. - Page 6 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.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
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. -
Page 8: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’... -
Page 9: Section 1 − Consignes De Securite
− SECTION 1 CONSIGNES DE SECURITE − LIRE AVANT UTILISATION 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. Y Identifie un message de sécurité particulier. Signifie NOTA ;... - Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. -
Page 13: Section 2 − Installation
SECTION 2 − INSTALLATION 2-1. Specifications Open- Circuit Circuit Rated Rated Model Model Voltage Voltage Welding Welding Range Output 200 A @ 28 200Amp Volts DC, 100% 14−39 Duty Cycle 250 A @ 35 250 Amp Volts DC, 100% 14−44 Duty Cycle 300 A @ 32 300 Amp... -
Page 14: Volt-Ampere Curves
2-3. Volt-Ampere Curves A. 250 Ampere Models B. 200 And 300 Ampere Models OM-259 Page 10 Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 − SA-180 902 / SA-180 901-A... -
Page 15: Dimensions And Weights
2-4. Dimensions And Weights 2-5. Selecting A Location Movement Location And Airflow 18 in (460 mm) 4 Holes 4 Holes ST-801 530 Tipping Y Do not move or operate unit where it could tip. Dimensions Dimensions Height 27-1/4 in (692 mm) Width 22-1/4 in (565 mm) Depth... -
Page 16: Slope Selection (250 Ampere Model)
2-6. Slope Selection (250 Ampere Model) SLOPE TURNS TAP SLOPE CONNECTIONS 1/2 in 3/8 in OM-259 Page 12 IMPORTANT: Be sure connections are clean before reconnecting tap. IMPORTANT: Move friction lug on PC1 to correct tab to insure proper operation of voltmeter preset. Slope Connection Label Tapped Reactor AC-Z And Slope Coils... -
Page 17: Inductance Selection (200 And 300 Ampere Models)
2-7. Inductance Selection (200 And 300 Ampere Models) Weld Bead Using The Tap Stabilizer Connection With 17 Volts, 100 Amps 3/8, 7/16 in 3/8 in Weld Bead Using The End Stabilizer Connection With 17 Volts, 100 Amps Stabilizer Z Tapped stabilizer Z is factory connected to the stabilizer tap which suits... -
Page 18: Weld Output Terminals And Selecting Cable Sizes
2-8. Weld Output Terminals And Selecting Cable Sizes Y 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. -
Page 19: Connecting To 115 Volts Ac Duplex Receptacle
2-10. Connecting To 115 Volts AC Duplex Receptacle 2-11. Electrical Service Guide 60 Hertz Models Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) -
Page 20: Placing Jumper Links And Connecting Input Power
2-12. Placing Jumper Links And Connecting Input Power 200 VOLTS 220 VOLTS L1 L2 L3 380 VOLTS L1 L2 L3 575 VOLTS THIS MACHINE DOES NOT REQUIRE Y Always connect grounding conductor first. = GND/PE 3/8, 1/2 in OM-259 Page 16 230 VOLTS 460 VOLTS 400 VOLTS... -
Page 21: Section 3 − Operation
SECTION 3 − OPERATION 3-1. Controls SECTION 4 − MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Replace Damaged Or Unreadable Labels Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or Vacuum Inside Power Switch Pilot Light Light is on when power is On. -
Page 22: Troubleshooting
4-2. Troubleshooting Trouble Completely inoperative; fan does not run. No weld output; fan motor FM running. Excessive line current; line fuse(s) and/or circuit breaker(s) open repeatedly. Weld output available; fan does not run. Fan runs slowly. Limited output and low open-circuit voltage. Erratic or improper weld output. -
Page 23: Section 5 − Electrical Diagrams
SECTION 5 − ELECTRICAL DIAGRAMS SB-183 958-A Figure 5-1. Circuit Diagram For 250 Ampere Model For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside the wrapper of the welding power source. SB-183 959 Figure 5-2. Circuit Diagram For 200 And 300 Ampere Models OM-259 Page 19... -
Page 24: Section 7 − Parts List
SECTION 6 − PARTS LIST ST-801 383-D Figure 6-1. Complete Assembly OM-259 Page 20... - Page 25 Item Dia. Part Mkgs....134 464 ....179 430 .
- Page 26 Item Dia. Part Mkgs.........
- Page 27 LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
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Page 28: Owner's Record
Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 1998 Miller Electric Mfg. Co. 9/98 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA &...
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