Miller Electric CP-252TS User's Manual
Contents
1. 1 074 188 LIGHT ind red lens 115VAC 1 172 587 a COVER Stud OUlPU asia ua teo ea IE Rae eed aise ere eed aleve dS 1 162 891 LABEL electric shock and reduced ari flow 1 009 433 HANDLE current control 1 009 926 PIN handle current control 1 160935 ss GLIP SONO ii EG er ich s 3 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 259 Page 29 4 Figure 6 3 Rectifier Assembly Ref 802 497 A Item Dia Par No Mkgs No Description Figure 6 3 Rectifier Assembly Figure 6 1 Item 17 aie wana aya 210 324 MOUNTING BOARD rectifier 2 AR EE a y aqa s 087 461 u HEAT SING uu tod tiu ta tede ke oe Want e lr dcc de 2 SR cl a 165 670 THERMOSTAT NC open 300F _ 1 d o peer 024 241 ANGLE mtg term wen A AAA 2 5 PLG1 158 720 CONNECTOR amp SOCKETS 1 6 SCR1 3 180456 THYRISTOR SCR 175 A30 3 7 AS RE 195 790 ASSEMBLY BRACKET rectifier 2 8 Aly VRT ss 089420 SUPPRESSOR FEEL 22339 2 1 99 It d etre ice teca atate ram t scena 1 9 oss Did sis 097956 1 44 DIODE T66t 275A SO0V iusti rp Pd RE DE Be EE Rd EA2. 1 it symbol Sage cs iie bte dts a OG b eiae dioe de 1 152 Are WVGIGING Hazards ses Dis eines Ged Di ER 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety Standards nn Rd EN Rote c o ee Ee i o 4 16 EMF IBIOHTIBUOD au see Deas SR ES Ss deed do wasnt eu teat nn a ace d aia Ru ds 4 SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 1 1 Signification des Symboles i b ek eR Stake a tees ea eee Ue edn dC es CU en 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTON 2 INSTALLATION 2 ey exar ee me bc er NEE 9 2 Speeilitalions tus aromas act Moe ous o Ve ous aute talus act va aw os hae d Ba 9 2 2 Duty Cycle And Overheating 4 en 9 2 3 VOlt ARIDBIG CIUEVOS S vods ae d dl nb Re e e Rei Rat EA ee se RR ie Nes 10 2 4 Dimensions And WelghtS o0ooooococonorr rr E A E E N e 11 2 5 elegi A LOCANO WEE 12 2 6 Typical MIG Process Connections Using A Constant Speed Wire Feeder 12 2 7 Typical MIG Process Connections Using A V
3. Unit overheated Allow unit to cool with fan on see Section 2 2 Check fuseable link see Section 4 2 Have Factory Authorized Service Agent check control relay CR1 Excessive line current line fuse s and or circuit breaker s open repeatedly Check for proper input connections see Section 2 15 Check for proper jumper link positions see Section 2 14 Weld output available fan does not run Check for and remove anything blocking fan blades Have Factory Authorized Service Agent check fan motor FM Fan runs slowly Check for proper jumper link positions see Section 2 14 Limited output and low open circuit voltage Check and replace open line fuse s see Section 2 15 Check for proper input connections see Section 2 15 Check for proper jumper link positions see Section 2 14 Erratic or improper weld output Check for proper jumper link positions see Section 2 14 Check for proper input connections see Section 2 15 Select correct size weld cables see Section 2 10 Clean and tighten weld cable connections see Section 2 10 Have Factory Authorized Service Agent adjust brush contact on slide wire For 250 ampere models check tap slope connections see Section 2 8 For 300 ampere models check inductance connections see Section 2 9 Install wire feeder according to it s Owner s Manual No 115 volts ac output at Remo
4. explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move
5. In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
6. es familiaris es avec les quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation Si la Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil Faire r guli rement contr ler et entretenir l installation Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur
7. not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away E ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the
8. or ship PC boards GN SS MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 43 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all
9. pri sec 220 380 415 No 1 top 1 3l saa 187 666 TRANSFORMER main power 380 520 302 models ICOTISISING Of s ig ose Pete AR dd 1 PS kuk aus 176 666 COIL pri sec 380 520 No 3 bottom 1 EE 176 665 COIL pri sec 380 520 No 2 center 1 N TETTE 176 664 COIL pri sec 380 520 No 1 top 1 BUN WEE N 187 665 TRANSFORMER power main 575V 302 model consisting of 1 OP rise 183 188 COIL pri sec 575 No 3 bottom 1 D A ENE ENO 183 187 COIL pri sec 575 No 2 center 1 ES MEER 183 186 i224 GOIL pri sec 575 NO 1 OD SERE EE an 1 ne OO did Msg posed odd 187 682 BAR MI transformer iis xis La a a in a 1 SO sms PO I sees 180264 CIRCUIT CARD firing 1 ONT 134 201 STAND OFF SUPPORT pc card A 37 AC2 177 336 REACTOR 252 model 1 OM 259 Page 27 Item Dia No Mkgs Par No STABILIZER 302 models BRACKET mtg PC board LABEL warning electric shock CONNECTOR clamp cable 1 250 SCREW 312 18 x 1 75 hexhd pln gr 5 FUSE PANEL module FUSE link LABEL warning electric shock hazard fuses replace INSULATOR cover fuse Description Figure 6 1 Complete Assemb
10. Or Replace Tighten Unreadable Cracked Weld Labels Cables And Terminals Cords Blow Out Or Vacuum Inside OM 259 Page 20 4 2 Overload Protection Disconnect and lockout tagout input power before removing side panel Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging cir cuit breaker or other disconnecting de vice 1 Fuse Panel Module Fuses F1 and F2 protect transformer T1 If one fuse link opens low weld output is available at output terminals If both fuse links open no weld output will be available at the output terminals gt Incorrect fuse can damage unit Use only replacement fuse of same size type and rating see Section 6 Replacing Fuse s Remove top and right side panels Replace open or damaged fuse s Reinstall side and top panels Tighten nuts to 65 in Ib 5 in Ib O 803 492 A OM 259 Page 21 4 3 Troubleshooting Trouble Remedy Completely inoperative fan does not run Place line disconnect switch in the On position see Section 2 15 Check and replace open line fuse s see Section 2 15 Check for proper jumper link positions see Section 2 14 Check for proper input connections see Section 2 15 No weld output fan motor FM running Reset circuit breakers CB1 and or CB2 if necessary see Section 2 12
11. av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal m 7 lation la r paration ou l entretien de l appareil Couper tiqueter e Sila ventilation est insuffisante utiliser un respirateur adduction l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor d air agr mes de s curit e m I le s Seet T i ase Ke e Lire les fiches techniques de sant s curit FTSS et les instruc en en tions du fabricant concernant les m taux les consommables les municipaux rev tements les nettoyants et les d graisseurs e Toujours v rifier la terre du cordon d alimentation V rifier et s assu e Netravailler dans un espace clos que s il est bien ventil ou porter un rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est racc
12. damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is sa
13. equipment in the welding area is electromagnetically compatible 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 elec tronic 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 shielded cables using line filters or shielding the work area OM 259 Page 3 1 4 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safet
14. flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 259 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder
15. from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som nd fre 7 02 1 1 ds ldentifie un message de s curit particulier Signification des symboles Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance Il y a des dangers li s aux CHOCS ELECTR
16. 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 current To in crease inductance and wet out the weld puddle connect to stabilizer Z ending To change inductance proceed as follows 2 Lead25 3 Stabilizer Z Tap 4 Stabilizer Z Ending 5 Lead 26 To increase inductance connect lead 26 to stabilizer ending and secure Reinstall side panel 6 Typical Weld Bead Using The Tap Stabilizer Connection Use the tap Stabilizer connection to obtain arc type and weld bead suit able for some mild steel applica tions 7 Typical Weld Bead Using The End High Stabilizer Connection Use the end Stabilizer connection to reduce weld bead crowning and spread the weld puddle L A L 4 Weld Bead Using The Tap Stabilizer Weld Bead Using The End Stabilizer Connection With 17 Volts 100 Amps Connection With 17 Volts 100 Amps JI 3 8 7 16 in CORO 3 8 in ST 801 379 B OM 259 Page 15 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 equi
17. metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby OA Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and
18. 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 puddle connect to a lower tap num ber 3 Leads 70 71 and 72 With Pressure Connectors Slide pressure connectors onto the same tap of each coil and secure them An unbalanced secondary current can damage the main transformer and cause errat ic weld conditions Be sure leads 70 71 and 72 are con nected to the same numbered slope turn tap on each coil See slope connection label 4 Firing Board PC1 5 Receptacle RC2 6 Lead 36 7 Receptacles RC3 Through RC6 Connect lead 36 from RC2 to correct receptacle RC4 RC5 RC6 or RC7 to match tap slope connec tions made in Section A as follows RC3 300A Used With 300A Mod els Only RCA for 4 turns RC5 for 6 turns RC6 for 8 turns IMPORTANT RC7 for 10 turns Be sure connections are clean Reinstall right side panel before reconnecting tap IMPORTANT Move friction lug on PC1 to correct tab to insure proper operation of voltmeter preset S 177 763 B Ref ST 801 518 A 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
19. volts ac circuits K Chassis common The remaining sockets are not used OM 259 Page 16 2 12 Connecting To 115 Volts AC Duplex Receptacle 2 13 Electrical Service Guide 1 remote 14 receptacle RC8 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts ac portion of RC8 and RC9 from overload CB2 protects 24 volts ac portion of RC8 from overload Press button to reset breaker Ref ST 801 380 B 60 Hertz Models 250 Amp Model 300 Amp Model Input Voltage 200 230 460 200 230 460 575 Input Amperes At Rated Output 34 5 30 15 38 33 16 5 13 Max Recommended Standard Fuse Rating In Am peres Time Delay 40 35 15 45 40 20 15 Normal Operating 3 50 45 20 60 50 25 20 Min Input Conductor Size In AWG Kcmil 8 10 14 8 8 12 14 Max Recommended Input Conductor Length In Feet 116 35 100 31 157 48 105 32 139 42 221 67 223 68 Meters Min Grounding Conductor Size In AWG Kcmil 10 10 14 10 10 12 14 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 50 Hertz Models 300 A
20. welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 7 02 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace
21. 4 JO C16 2222s 031089 i CAPACITOR TER disease ea 6 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 259 Page 30 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Effective January 1 2002 Equipment with a serial number preface of LC or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied 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 THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing with
22. AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 6 02 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg Co Heplacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA D I Internation
23. Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts Miller MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT
24. IQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de connaitre les me gt Signifie lt NOTA gt n est pas relatif la s curit sures prendre pour viter tout danger 1 2 Dangers relatifs au soudage l arc A Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apr s ne font que r sumer le contenu des normes de s curit mentionn es la section 1 4 Lire et respecter toutes ces normes N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants e Ps LES D CHARGES LECTRIQUES e
25. Input at Rated Load Output 50 or 60 Hz Three Phase Rated Circuit Model rt a 200 220 230 380 400 440 460 520 575 y kw DC V V V V V V V V V 250 A 35 AO Ne De oo as sese LA debe es ea ME he oa ee Duty Cycle 300 32 E 38 345 33 20 19 173 165 146 13 0 13 1 12 3 300 Amp is De 100 1444 3 28 2 7 19 16 1 5 14 1 1 0 7 0 97 0 68 uty Cycle While idling 2 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding Exceeding duty cycle can damage unit and void warranty 100 Duty Cycle 0 Lr Y Li Q gt lt m m 25 30 40 50 60 e SID CST LES A V EN XL 3 EN Reduce Duty Cycle Continuous Welding Overheating Minutes duty1 4 95 Ref SA 177 714 B OM 259 Page 9 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 50 po SEE MAX VOLTAGE D C VOLTS 50 100 150 200 250 300 D C AMPERES B 300 Ampere Models 50 40 ER 20 EE VOLTS 10 O SE OE deg DU 220 SUB SOU ER 42560 DC AMPERES va curv
26. NE DOES NOT REQUIRE SUPPLIED JUMPER LINKS OL OL OL S 183 223 J 3 8 1 2 in CLEO 3 8 1 2 in Ref ST 801 382 OM 259 Page 18 2 15 Connecting Input Power n 7 iB J BW Www www ei TS TST SI N N gg uud ei 9 P s e Sn O When making connections in the line disconnect device connect the Green Or Green Yellow conductor first Install conductors into a deenergized line disconnect device Make connections to machine first and Supply last Tools Needed S 3 8 in 1 2 in C E00 3 8 in 1 2 in Disconnect and lockout tagout input power before connecting input con ductors from unit Have only qualified persons make this installation See rating label on unit and check input volt age available at site 1 Line Disconnect Device 2 Input Conductors 3 Grounding Conductor Select size and length using Section 2 13 Conductors must comply with national state and local electrical codes Use lugs of proper amperage capacity and correct hole size PR Z Y wwe GND PE Earth Ground Ez IMPORTANT Tighten nuts to 65 in Ib 5 in Ib GND PE Connect Green Or Green Yellow 4 Strain Relief Route conductors through strain relief 5 Machine Grounding Terminal 6 Line Terminals Make input power connections to the welding power source before making connections into a deenergized line disconnect device Connect green or green y
27. OM 259 177 743P June 2003 Miller S MIG GMAW Welding Flux Cored FCAW Welding Description i E3 pc Arc Welding Power Source CP 302 and CP 252TS imi OWNER S MANUAL Visit our website at www MillerWelds com 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 build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir U E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Deeds EE jue EE You e i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Wl 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALIT
28. Y SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in Dosen exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P 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 orindividual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web ur Miller 44 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq The following term is used interchangeably throughout this manual MIG GMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
29. adduction d air Les e Ne pas toucher l lectrode quand on est en contact avec la pi ce la rev tements et tous les m taux renfermant ces l ments peuvent d terre ou une lectrode d une autre machine gager des fum es toxiques lorsqu on les soude OM 259 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage e Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 e Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit gt H LE SOUDAGE peut causer un incen 3 die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipemen
30. al Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 uu International FAX 920 735 4125 Circuit Diagrams European Headquarters United Kingdom Welding Process Handbooks Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2003 Miller Electric Mfg Co 1 03
31. de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 259 Page 7 1 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet c
32. e de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque e Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu gt SC vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 259 Page 6 LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de E non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr LES PI CES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les pe
33. e welding _ n FCAW contact welding wire Wire Feeder manufacture for polarity rec ommendations Shielding Gas When Required Electrode Lead Work Lead Workpiece A Work Clamp mig 9 99 Ref ST 800 357 A OM 259 Page 12 2 7 Typical MIG Process Connections Using A Voltage Sensing Wire Feeder Work Clamp Voltage Sensing Clamp Constant Current CC Or Constant Voltage CV Power Source Voltage Sensing Wire Feeder Electrode Lead Work Lead Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Voltage sensing wire feeders are used with constant current CC or constant voltage CV power sources 14 pin receptacle not re duired If using a CC welding power source without a weld output contactor use optional secondary contactor For GMAW use optional gas valve 802 488 OM 259 Page 13 2 8 Slope Selection 250 Ampere Model 7 SLOPE TURNS TAP SLOPE CONNECTIONS OM 259 Page 14 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 Slope Coils Tapped
34. e1 4 95 SA 180 902 SA 180 901 B OM 259 Page 10 2 4 Dimensions And Weights 4 Holes 800 453 A 801 530 Dimensions 30 in 762 mm Including lift eye 23 in 584 mm 31 in 787 mm Including strain relief 27 1 2 in 699 mm 3 4 in 19 mm 21 1 8 in 537 mm 1 1 8 in 29 mm 7 16 in 11 mm Dia Weight 320 Ib 145 kg OM 259 Page 11 2 5 Selecting A Location 1 Rating Label Use rating label to determine input power needs Label located under front access door Tippin Movement pping 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 INPUT SERIAL NO STOCK NO VOLTS AMPERES KW Ref ST 801 378 B 2 6 Typical MIG Process Connections Using A Constant Speed Wire Feeder A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a 14 Pin Interconnecting Cord vehicle Place work clamp as close to the weld as possible Regulator Constant Constant speed wire feeders are Flowmeter Voltage used with constant voltage CV el m CV power sources having a 14 pin re Bk BER Welding ceptacle Su F fl d Idi Source gt For flux cor
35. ellow grounding con ductor to machine grounding terminal first Then connect input conductors to line termi nals Close access door 7 Disconnect Device Supply Grounding Terminal 8 Disconnect Device Line Terminals GND PE Conductor First In the deenergized line disconnect de vice connect green or green yellow grounding conductor to supply grounding terminal first never to a line terminal Be sure grounding conductor goes to an earth ground Connect input conductors to line terminals 9 Overcurrent Protection Select type and size using Section 2 13 fused disconnect switch shown Close door on line disconnect device ST 800 103 B Ref ST 801 116 OM 259 Page 19 SECTION 3 OPERATION 3 1 Controls 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 Voltage Adjustment control When light is off the voltmeter displays actual welding voltage while welding Weld output terminals are energized only when the preset indicator light is Off Voltage Adjustment Control Voltmeter Ammeter Ref ST 801 380 B SECTION 4 MAINTENANCE amp TROUBLESHOOTING 4 1 Routine Maintenance A Disconnect power gt Maintain more often before maintaining during severe conditions 3 Months Replace Repair Or Clean And Damaged
36. envisag e les maintenir en bon tat ainsi que les pi ces connexes D tourner la t te lorsqu on ouvre la soupape d une bouteille Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit 1 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle e Ne pasinstaller l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que l anneau de levage pour lever lap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op rato
37. euibue dojs Jo Jamod ndu 3joeuuooSiQ e suyod D24122l an yono jou oq OUVZVYH AJOHS Ol419313 ONINSVM Y 3AULISOd ERR NOOS OZS 097 0 3 WE E AYVNIY d LIA 09 0 2 002 212 994 A H d D u uD voel DY VU U UU AMA AL LE Kaf H Il 2 Gl el El ah FL sl a A022 A007 Advy Adee ARIS or 6 a LA 0Y9 00y 022 L g e o AYUNIVA 170A 02S 08 IL 8 9 L o Oa OL AdVNWIdd LIDA SLS S3INvWIMd VNOIL dO For 300 Ampere Models it Diagram IFCUI Figure 5 2 C OM 259 Page 24 Notes OM 259 Page 25 SECTION 6 PARTS LIST Fig 6 2 30 801 383 J OM 259 Page 26 Item Dia Par No Mkgs No Description Quantity Figure 6 1 Complete Assembly ae NU RE N 134 464 LABEL warning general 2 O mie 1794304 PANEL SIde iu ainia dete de fiut 2 nc cT 1794294 COVER NOD iria 1 iar Ele at au s gue us 77 2791 I GASKET IR SYS cust te quo dnd Enc een enorme Du Q ts 1 gu RE EED 162 090 er HFT Ve EER ESE ED E EE Sao aa 1 E TR PM 162 820 BAR mtg lift eye EE att ui eR Rar Rar n E EE hae eet ae aln le db aM dod 2 Eua soe VEN Pasa 038 138 TERMINAL ASSEMBLY p
38. fe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 259 Page 1 ARC RAYS can burn eyes and skin 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 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 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection T WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to
39. horizontal 2 N RE EE OE 210 708 COLUMN brush rigging 1 NOU in Mie E 024 622 NUT 625 11 1 00 hex 50h stl 2 set screws 2 uL T 190 100 HOLDER brush assembly consisting of 3 MUR 190 103 HOLDER DrisS tack stats Den ea bi ie SAG PR di 1 MS DEE N ass 190 107 BRUSH SET contact elect 2 2224 DEd REESE PEERS 1 MINES 190 106 RETAINER brush holder sit iss se Here 2 1 TT EIE EL 018 606 SPRING CDSM 2 25099 4 quos ast Aa RE BR RENE RSR EUR ces 5 RE ROC 190 105 SPACER brush holder 2 poss eet ese ed EN OR DE N FRONT PANEL ASSEMBLY Figure 6 2 1 N AAR 2 187 664 TRANSFORMER main power 200 230 460 consisting of 1 D EI 176 602 COIL pri sec 200 230 460 No 3 bottom 1 ME N ET N 176 601 COIL pri sec 200 230 460 No 2 center 1 Ode etat 176 600 COIL pri sec 200 230 460 No 1 top 1 rco NP 187 667 TRANSFORMER main power 220 400 440 302 models COMSISUAG OP 2 a sluku Durante cog V ERES edit ee 1 M e ERREUR 176 770 COIL pri sec 220 380 415 No 3 bottom 1 iGO EEN 176 769 COIL pri sec 220 380 415 No 2 center 1 m A 176 767 COIL
40. in thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers nverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models
41. ire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste LES CHARGES ELECTROSTATI OUES peuvent endommager les cir cuits imprim s EA o GN e Mettre un bracelet antistatigue AVANT de mani puler des cartes ou des pieces e Utiliser des pochettes et des bo tes antistatigues pour stocker d placer ou exp dier des cartes de circuits imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pieces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage LES ORGANES MOBILES peuvent causer des blessures e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs Ne demander qu des personnes qualifi
42. ly continued Quantity BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Item Dia No Mkgs OM 259 Page 28 Part No 181 246 Figure 6 2 Panel Front w Components Description Ref 802 497 Figure 6 2 Panel Front w Components Figure 6 1 Item 30 vas FRONT PANEL 2 zz eem TERMINAL power output black SPRING cprsn 600 OD x 072 SWITCH tgl 3PST 40A 600V TERMINAL power output red NAMEPLATE order by model and serial number RELAY encl 24VAC DPDT Item Dia No Mkgs 8 2 8 OR2 Oats RZ asie ace 10 RC8 1 sis RED ia 2 12 CB1 2 oc A N VA DER nn RR 19 2 PE 17 PEZ 223 210 34 miis we ETETE Be Kr EEN 0 TP h ieee ee N E NTC Part No Description Figure 6 2 Panel Front w Components continued Figure 6 1 Item 30 186 162 RELAY encl 120VAC DPDT 1 114 050 RESISTOR WW fxd 10W 1K ohm 1 143 976 RECEPTACLE SOCKETS 1 604 176 RECEPTACLE str dx grd 2PSW 15A 125V 1 093 995 CIRCUIT BREAKER man reset IP 15A 250VAC 2 1760532 BAFFLE BI 222 022 Si ER ER Ea Sade ec IU ES 1 119 005 METER amp DC 50MV 0 400 1 118 902 METER volt DC 0 50 1 163 562 LIGHT ind wht lens 115VAC
43. mp Model Input Voltage 220 380 400 440 520 Input Amperes At Rated Output 34 5 20 19 17 3 14 6 Max Recommended Standard Fuse Rating In Amperes Time Delay 40 25 20 20 15 Normal Operating 3 50 30 30 25 20 Min Input Conductor Size In AWG Kcmil 8 12 12 12 14 Max Recommended Input Conductor Length In Feet Meters ed E SE S6 Min Grounding Conductor Size In AWG Kcmil 10 12 12 12 14 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 259 Page 17 2 14 Placing Jumper Links 3 Check input voltage available at site D E 1 Jumper Link Label Check label only one is on unit 2 Jumper Link Move jumper links to match input volt age and label on unit Tighten jumper link nuts to 25 in Ib 5 in Ib 200 VOLTS 230 VOLTS 460 VOLTS AA 28 AA AA e Glen AMAA MR Me Me M L1 L2 L3 L1 L2 L3 L1 L2 L3 S 072 135 B 220 VOLTS 400 VOLTS 440 VOLTS A AR M AR M AR o oA o o office o o A o e of o e oA o o o of o o o Lio L2e L3 e Lie L26 L3 e Lio L2e L3 S 177 581 380 VOLTS 520 VOLTS o oo o oo Ao o oo Ao o o o A o ooo Ao o oo Ao Lio L20 L3 oLtoL20o L3 S 177 582 575 VOLTS 000000 000000 o00000 THIS MACHI
44. nt pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu lt Laccumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiquespendant le soudage ou le coupage OM 259 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 2 INSTALLATION 2 1 Specifications Open Amperes
45. oltage Sensing Wire Feeder 13 2 8 Slope Selection 250 Ampere Model 14 2 9 Inductance Selection 300 Ampere Models 15 2 10 Weld Output Terminals And Selecting Cable Sizes 16 2 11 Remote 14 Receptacle Iotormmatnon sense eneeneene nennen een 16 2 12 Connecting To 115 Volts AC Duplex Receptacle 17 2 13 Electrical Service Guide keene een hrs 17 2 14 Placing Jumper GINKS 3 aoe cours awe ee nr adie dae eee beeen a 18 2 15 Connecting INDUL POWER bees SE A EE afe ER 19 SECTION 3 OPERATION ouvir in ha ea Ee oe es in ai 20 JA GOTO PRETENDE ENTENDER 20 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 20 2 1 Routine MAINTENANCE si RE RE ma iet trc ic ehe 20 4 2 Overload PEOIGOHOU his iis ER BE bene ean ine Ree dte ara a ae ur ERO ae ee 21 4235 HOUBIESNOOUNG EER db oed eund d e e OE DE ten a ie atom Dac wer out 22 SECTION 5 ELECTRICAL DIAGRAMS oe n EE ced Rx EEN EN mm a 23 SECTION 6 PARTS LIST eae eise SG RB RE en FUE m akal uuu kaa eu hd 26 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ds Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols gt Means Note
46. om Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs reste
47. ord e une prise correctement mise la terre Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution respirateur adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou tante mal piss s e Ne pas souder de m taux munis d un rev tement tels que la t le e Ne pas s enrouler les c bles autour du corps d acier galvanis e plomb e ou cadmi e moins que le rev tement e Sila pi ce soud e doit tre mise la terre le faire directement avec un n ait t enlev dans la zone de soudage que l endroit soit bien venti c ble distinct l et si n cessaire porter un respirateur
48. peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact Ne pas connecter plus d une lectrode ou plus d un c ble de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger Ne jamais toucher aux pi ces lectriques sous tension Porter des gants et des v tements de protection secs et exempts de trous S isoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige Si l utilisation d une source de courant alternatif s
49. pment 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 shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding Ba mr N NE aon ason aon 2 10 60 60 100 output terminals Amperes QUY Duy 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes 2 11 Remote 14 Receptacle Information S 0007 E LA remore 14 Socket Socket Information A 24 volts ac Protected by circuit breaker CB2 B Contact closure to A completes 24 volts ac contactor control circuit OUTPUT 115 volts 15 amperes 60 Hz ac Protected by circuit breaker CB1 CONTACTOR olo FEEDER J Contact closure to completes 115 volts ac contactor control circuit G Circuit common for 24 and 115
50. ri consisting of 1 EE ORR EE SONE 038 618 22 JUMPER dink rs pe race nn SG gay aieo GE a a lage 6 1279 ae FM os 208 402 MOTOR fan 1 12HP 230V 1550R 1 Lc dstes 124 274 BRACKET MIO fani MOLOF uie auia ne 1 n3 dave Stet det 1702838 GHAMBER En n RER 1 e NE EN 180 165 BLADE fan 14 000 3wg 28D 1 TN UL MT 162807 PANEL TER er Es eoru ee tte Moe ace Ee bite 1 WO RE EER EG 168343 HINGE acce EN ee ritas di ed ee 2 dIE pena 162 818 DOOR access primary 1 mo ET 168 384 LABEL warning electric shock 1 md sie OR 243 180 198 RECTIFIER assembly Figure 6 3 1 ek der Da ain 195 799 4 ASSEMBLY SIU eas nn Ed de m pacte eege Eech ode 1 I ER oe 162 816 CHANNEL upright 4 ES OD EER oe 180 455 5 BASE rs nn a EE RS one Ma actam ee e ia 1 a TE 190 101 RIGGING ASSEMBLY brush consisting of 1 Eech 176 635 BRACKET mtg vertical 2 nc pari nie 187 677 BRACKET mtg horizontal 4 210 709 SCREW lead u iuo iot t dae ee uen rene 1 EED TEZ LL gz 190 102 MOUNTING bd brush holder 1 ia EE ER 187 678 BAR frame
51. rsonnes qui portent un stimulateur cardiaque doivent se tenir distance e lls doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteiles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution endommag es e Prot ger les bouteilles de gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N tiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application
52. te 14 receptacle RC8 Reset circuit breaker CB1 if necessary see Section 2 12 No 24 volts ac output at Remote 14 receptacle RC8 Reset circuit breaker CB2 if necessary see Section 2 12 Limited output Check fuseable link see Section 4 2 OM 259 Page 22 SECTION 5 ELECTRICAL DIAGRAMS C CO a tou gt ZO TUYO O VON gt gt lr B n v 9 J sl e O EC u gt 19 d lt 1208 da id e TOs L LOL gt O SS lt 8 8 33 aa EE NN 6 ti Li de M VV VV VV SOTTO CD NIMMT FU mir Ye Ed DIN o yo OD 0L Oo oz ho B O ZU CN OZ DE 4 2 N EN X va S 99 GO 9 O ER SOd ca La T O CO maa iim a Ze LE oO DAS u T 0000 0001 0000 0001 0900 00090 d H SU I ees 5 O TL ama et gt lt lt 2 S A gt lt Y T o De Re We NZ m e Ro Ty Re e Q bal bal Noe DEZ 097 OFZ 002 ONS LS 3 IO OOO I o 9 o N 5 7 OU o n 1 iun siy eones jo een JAHVZVH MOOHS IDISUI suosiod paijipnb AjuoO 8ADH x 91419313 PSAOLUSJ S19A09 UMA ayojado jou OQ Buldinlas a40jag aulbua dois jo Jamod jndui joeuuoosSiQg x sUDd D24128le SAI yono jou oq ss 212 993 A For 250 Ampere Model ircuit Diagram Figure 5 1 C OM 259 Page 23 3ALV93N Ho MOT es HUN siy 851M8S Jo esn IDISUI suosiod p ipjonb AjUO 9ADH s Pe ouj8J S19A09 JIM a DJado jou og bulones a10jag
53. ts chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud e Ne pas souder un endroit o des tincelles peuvent tomber sur des substances inflammables e Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit e Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t e Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie e Ne pas utiliser le post
54. y in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 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 committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 259 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B
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