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Miller Electric CP-202 manual

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Table of contents for the manual

  • Page 1

    Processes Descrip tio n MIG (GMAW ) W elding Flux Cored (FCA W ) W elding Arc Welding Power Source OM -259 177 743E May 1998 CP-202, CP-302, and CP-252TS V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor call 1-800-4-A-Miller . Thank you and congratulations on choosing Miller [...]

  • Page 3

    The following terms are used interchangeably throughout this manual: MIG = GMAW Flux Cored = FCAW T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-259 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch 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. This group of symbols means W arning! Watch O[...]

  • Page 6

    OM-259 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D 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[...]

  • Page 7

    OM-259 Page 3 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. F A[...]

  • Page 8

    OM-259 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 o[...]

  • Page 9

    OM-259 Page 5 SECTION 1 − CONSIGNES DE SECU RITE − LIRE A V ANT UTILISA TION 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. Y Identifie un message de sécurité particulier . . Signif[...]

  • Page 10

    OM-259 Page 6 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. LES R A YONS DE L ’ARC peuvent pro- voquer des brûlures dans les yeux et sur la[...]

  • Page 11

    OM-259 Page 7 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’installatio[...]

  • Page 12

    OM-259 Page 8 1-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American W el- 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 Of fice, Washington, D.C. 20402. Recommended Safe Practice for the Prep[...]

  • Page 13

    OM-259 Page 9 SECTION 2 − INST ALLA TION 2-1. Specifications Model Rated W elding Open- Circuit V oltage Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model Rated W elding Output Circuit V oltage Range DC 200 V 220 V 230 V 380 V 400 V 440 V 460 V 520 V 575 V KV A KW 200Amp 200 A @ 28 V olts DC, 100% Duty Cycle 14−39 21.9 3* 19.1 [...]

  • Page 14

    OM-259 Page 10 2-3. V olt-Ampere Curves va_curve1 4/95 − SA-180 902 / SA-180 901-A V olt-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[...]

  • Page 15

    OM-259 Page 1 1 2-4. Dimensions And Weights C Dimensions D C Dimensions E 4 Holes D Height 27-1/4 in (692 mm) 4 Holes Width 22-1/4 in (565 mm) Depth 28-1/4 in (717 mm) A 27-1/2 in (698 mm) A B 3/4 in (19 mm) A C 21 in (533 mm) D 1-3/16 in (30 mm) E 7/16 in (1 1 mm) Dia W eight ST-801 530 B 320 lb (145 kg) 2-5. Selecting A Location 1 Rating Label Us[...]

  • Page 16

    OM-259 Page 12 2-6. Slope Selection (250 Ampere Model) Ref. ST-801 518-A 1 Slope Connection Label 2 T apped Reactor AC-Z And Slope Coils T apped 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. T o increase inductance and wet out t he weld pu[...]

  • Page 17

    OM-259 Page 13 2-7. Inductance Selection (200 And 300 Ampere Models) 1 Stabilizer Z T apped stabilizer Z is factory connected to the stabilizer tap which suits most GMAW applications. Stabilizer Z controls the inductance applied to the weld current. T o in- crease inductance and wet out the weld puddle, connect to stabilizer Z ending. T o change in[...]

  • Page 18

    OM-259 Page 14 2-8. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o 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 [...]

  • Page 19

    OM-259 Page 15 2-10. Connecting T o 1 15 V olts AC Duplex Receptacle Ref. ST-801 380-B 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9 a n d remote 14 receptacle RC8. 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB 1 protects 1 15 volts ac portion of RC8 and RC9 from overload. CB2 protects 24 volts ac portion of RC8 from overload. Press[...]

  • Page 20

    OM-259 Page 16 4 2-12. Placing Jumper Links And Connecting Input Power ST-801 382 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 voltage, and label on unit. 3 Input And Grounding Conductors See Section 2-1 1. 4 Line Disconnect Device See Section 2-1 1. C[...]

  • Page 21

    OM-259 Page 17 SECTION 3 − OPERA TION 3-1. Controls Ref. ST-801 380-B 1 Power Switch 2 Pilot Light Light is on when power is On. 3 Preset Indicator Light When light is on, the voltmeter displays preset welding voltage as selected by the V oltage Adjustment control. When light is of f, the voltmeter displays actual welding voltage while welding. Y[...]

  • Page 22

    OM-259 Page 18 4-2. T roubleshooting T rouble Remedy Completely inoperative; fan does not run. Place line disconnect switch in the On position. Check and replace open line fuse(s) (see Section 2-1 1). Check for proper jumper link positions (see Section 2-12 ). Check for proper input connections (see Section 2-12 ). No weld output; fan motor FM runn[...]

  • Page 23

    OM-259 Page 19 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[...]

  • Page 24

    OM-259 Page 20 SECTION 6 − P ARTS LIST Figure 6-1. Complete Assembly ST-801 383-D 1 2 4 5 6 7 10 11 12 13 1 4 15 16 17 18 19 1 20 22 23 24 25 26 27 21 28 30 31 32 29 33 34 35 36 8 9 37 3[...]

  • Page 25

    OM-259 Page 21 Quantity Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly 1 134 464 LABEL, warning general 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 179 430 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 26

    OM-259 Page 22 Quantity Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly (Continued) FRONT P ANEL ASSEMBL Y , (continued) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC9 604 176 RECEPT ACLE, str dx grd 2P3W 15A 125V 1 . . . . . . . . . . . . . . . . . . . [...]

  • Page 27

    Effective January 1, 1998 (Equipment with a serial num ber preface of “KJ” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED W ARRANTY − Subject to the terms and conditions below , Miller Electric Mfg. Co., Appleton, Wisconsin, warran[...]

  • Page 28

    PRINTED IN USA  1998 Miller Electric Mfg. Co. 9/98 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West S pencer Street Applet on, WI 5 4914 US A International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada FAX: 920-735-4134 Int ernati onal F A X : 920-735-4125 European Headquarte rs − United [...]