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Miller CP 302 Manual
Miller CP 302 Manual
Miller CP 302 Manual
December 2003
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
CP-302
Mil_Thank 7/03
TABLE OF CONTENTS
Y Marks a special safety message. 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
. Means “Note”; not safety related. to avoid the hazards.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
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 Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion. D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks, going near arc welding, gouging, or spot
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see
gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
300 A @ 32
38 34.5 33 20 19 17.3 16.5 14.6 13.0 13.1 12.3
300 Amp Volts DC, 100% 14−44
1.1* 1.0* 0.95* 0.60* 0.55* 0.50* 0.48* 0.43* .38* 0.38* 0.32*
Duty Cycle
*While idling
Continuous Welding
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 / Ref. SA-177 714-B
CP302 MIN
Dimensions
A
A 30 in (762 mm) Including lift eye
B 23 in (584 mm)
F
E 3/4 in (19 mm)
G
H
4 Holes
F 21-1/8 in (537 mm)
D
H 7/16 in (11 mm) Dia
Weight
18 in
(460 mm)
18 in
(460 mm) Ref. ST-801 378-B
3-6. Typical MIG Process Connections Using A Constant Speed Wire Feeder
Y 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)
(CV) power sources having a 14-pin re-
Welding ceptacle.
Power
Constant Source . For flux cored welding
Speed (FCAW), contact welding wire
Wire Feeder manufacture for polarity rec-
ommendations.
Shielding Gas
Gun (When Required)
Gas
Workpiece
Electrode Lead
Work Clamp
Work Lead
802 488
4
3
6 7
Weld Bead Using The Tap Stabilizer Weld Bead Using The End Stabilizer
Connection With 17 Volts, 100 Amps Connection With 17 Volts, 100 Amps
3/8, 7/16 in
3/8 in
ST-801 379-B
10 − 60% 60 − 100%
Connecting to weld Welding
Duty Duty 10 − 100% Duty Cycle
output terminals Amperes
Cycle Cycle
*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 mm2 equivalent weld cable sizes. S-0007-E
A J
K I G Circuit common for 24 and 115 volts ac circuits.
B
C L N H
D M G
E F K Chassis common.
60 Hertz Models
Time-Delay 2 45 40 20 15
Normal Operating 3 60 50 25 20
Max Recommended Input Conductor Length In Feet (Meters) 105 (32) 139 (42) 221 (67) 223 (68)
50 Hertz Models
Time-Delay 2 40 25 20 20 15
Normal Operating 3 50 30 30 25 20
L1 L2 L3 L1 L2 L3 L1 L2 L3
S-072 135-B
1
220 VOLTS 400 VOLTS 440 VOLTS
L1 L2 L3 L1 L2 L3 L1 L2 L3
S-177 581
L1 L2 L3 L1 L2 L3
S-177 582
575 VOLTS
THIS MACHINE DOES NOT REQUIRE
SUPPLIED JUMPER LINKS.
S-183 223
3/8, 1/2 in
3/8, 1/2 in
Ref. ST-801 382
4
3
When making connections in
the line disconnect device,
connect the Green Or
Green/Yellow conductor first.
Tools Needed: L1 L2 L3
Y Disconnect and lockout/tagout input 4 Strain Relief Y In the deenergized line disconnect de-
power before connecting input con- Route conductors through strain relief. vice, connect green or green/yellow
ductors from unit. 5 Machine Grounding Terminal grounding conductor to supply
grounding terminal first, never to a line
Y Have only qualified persons make this 6 Line Terminals terminal. Be sure grounding conductor
installation. Y Make input power connections to the goes to an earth ground.
welding power source before making
See rating label on unit and check input volt- connections into a deenergized line Connect input conductors to line terminals.
age available at site. disconnect device. 9 Overcurrent Protection
1 Line Disconnect Device Connect green or green/yellow grounding con- Select type and size using Section 3-12 (fused
ductor to machine grounding terminal first. disconnect switch shown).
2 Input Conductors
Then connect input conductors to line termi-
3 Grounding Conductor nals. Close door on line disconnect device.
Select size and length using Section 3-12. Close access door.
Conductors must comply with national, state, 7 Disconnect Device (Supply) Grounding
and local electrical codes. Use lugs of proper Terminal
amperage capacity and correct hole size. 8 Disconnect Device Line Terminals
ST-800 103-B / Ref. ST-801 116
4-1. Controls
1 Power Switch
2 Pilot Light
Light is on when power is On.
3 Preset Indicator Light
5 6 When light is on, the voltmeter
1 displays preset welding voltage as
selected by the Voltage Adjustment
2 control.
3 When light is off, the voltmeter
displays actual welding voltage while
welding.
Y Weld output terminals are
energized only when the
preset indicator light is Off.
4
4 Voltage Adjustment Control
5 Voltmeter
6 Ammeter
3 Months
6 Months
Blow Out Or
Vacuum Inside
. Tighten nuts to 65 in lb
+/- 5 in lb.
3/8 in
1/2 in
803 492-A
Trouble Remedy
Completely inoperative; fan does not run. Place line disconnect switch in the On position (see Section 3-14).
No weld output; fan motor FM running. Reset circuit breakers CB1 and/or CB2, if necessary (see Section 3-11).
Unit overheated. Allow unit to cool with fan on (see Section 3-2).
Excessive line current; line fuse(s) and/or circuit Check for proper input connections (see Section 3-14).
breaker(s) open repeatedly.
Weld output available; fan does not run. Check for and remove anything blocking fan blades.
Fan runs slowly. Check for proper jumper link positions (see Section 3-13).
Limited output and low open-circuit voltage. Check and replace open line fuse(s) (see Section 3-14).
Erratic or improper weld output. Check for proper jumper link positions (see Section 3-13).
Have Factory Authorized Service Agent adjust brush contact on slide wire.
No 115 volts ac output at Remote 14 receptacle RC8. Reset circuit breaker CB1, if necessary (see Section 3-11).
No 24 volts ac output at Remote 14 receptacle RC8. Reset circuit breaker CB2, if necessary (see Section 3-11).
212 994-A
15
14
39
13
12
17
43
44
42
11
41
1
10
19
7
40
6
5
4
38
20
37
36
22
23
21
24
3
25
26
28
29
35
27
2
31
1
30
11
10
9
8
7
14 13
6
15
4
23
16
3
17
5
18 2
19 20
21
1
22
Figure 7-2. Panel, Front w/Components (contined) (Figure 7-1 Item 30)
6 4
7
2
1
10
9
Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* APT & SAF Model Plasma Cutting Torches
for your local after the effective date of this limited warranty is free of defects * Remote Controls
in material and workmanship at the time it is shipped by Miller. * Accessory Kits
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast,
warranty claim procedures to be followed. relays or parts that fail due to normal wear.
reliable response you (Exception: brushes, slip rings, and relays are
need. Most replacement Miller shall honor warranty claims on warranted equipment
covered on Bobcat, Trailblazer, and Legend models.)
parts can be in your listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that 2. Items furnished by Miller, but manufactured by others,
hands in 24 hours. the equipment was delivered to the original retail purchaser, or such as engines or trade accessories. These items are
Support one year after the equipment is sent to a North American covered by the manufacturer’s warranty, if any.
Need fast answers to the distributor or eighteen months after the equipment is sent to an
International distributor. 3. Equipment that has been modified by any party other
tough welding questions? than Miller, or equipment that has been improperly
Contact your distributor. 1. 5 Years Parts — 3 Years Labor installed, improperly operated or misused based upon
The expertise of the * Original main power rectifiers industry standards, or equipment which has not had
distributor and Miller is reasonable and necessary maintenance, or equipment
* Inverters (input and output rectifiers only) which has been used for operation outside of the
there to help you, every
2. 3 Years — Parts and Labor specifications for the equipment.
step of the way.
* Transformer/Rectifier Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Plasma Arc Cutting Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Semi-Automatic and Automatic Wire Feeders AND MAINTENANCE OF WELDING EQUIPMENT.
* Inverter Power Supplies In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Maxstar 150 appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor Unless Specified replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
Spoolguns)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
* Flowgauge and Flowmeter Regulators (No Labor)
REPRESENTATION AS TO PERFORMANCE, AND ANY
* HF Units REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Grids OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Maxstar 85, 140 OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Spot Welders OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Load Banks PURPOSE, WITH RESPECT TO ANY AND ALL
* Racks EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Running Gear/Trailers DISCLAIMED BY MILLER.
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long
Models) an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
* Field Options limitation or exclusion may not apply to you. This warranty
(NOTE: Field options are covered under True provides specific legal rights, and other rights may be
Blue for the remaining warranty period of the available, but may vary from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may
* MIG Guns/TIG Torches be available, but may vary from province to province.
miller_warr 8/03
Owner’s Record
Please complete and retain with your personal records.
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.
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.