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Miller Electric CP-252TS, Owner'S Manual

The Miller Electric CP-252TS is a powerful welding machine perfect for industrial use. Ensure optimal performance by referring to the Owner's Manual available for free download at manualshive.com. This comprehensive manual provides step-by-step instructions for setup, operation, and maintenance, ensuring the longevity of your equipment.

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OM-259 Page 27

Quantity

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 6-1. Complete Assembly

1

134 464

LABEL, warning general

2

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

179 430

PANEL, side

2

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

179 429

COVER, top

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

177 279

GASKET, lift eye

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

162 830

LIFT, eye

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

162 820

BAR, mtg lift eye

2

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

TE1

038 138

TERMINAL ASSEMBLY, pri (consisting of)

1

. . . 

. . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

038 618

JUMPER, link

6

. . . . . . . . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

FM

208 402

MOTOR, fan 1/12HP 230V 1550R

1

. . . 

. . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

124 274

BRACKET, mtg fan motor

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

10

173 283

CHAMBER, plenum

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

180 165

BLADE, fan 14.000 3wg 28D

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

162 807

PANEL, rear

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13

168 343

HINGE

2

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

162 818

DOOR, access primary

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15

168 384

LABEL, warning electric shock

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

SR1

180 198

RECTIFIER, assembly (Figure 6-3)

1

. . . 

. . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18

195 793

ASSEMBLY, shunt

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

162 816

CHANNEL, upright

4

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

20

180 455

BASE

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

190 101

RIGGING ASSEMBLY, brush (consisting of)

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . 

22

176 635

BRACKET, mtg vertical

2

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

187 677

BRACKET, mtg horizontal

4

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

210 709

SCREW, lead

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

TE2

190 102

MOUNTING, bd brush holder

1

. . . 

. . . 

. . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

26

187 678

BAR, frame horizontal

2

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

27

210 708

COLUMN, brush rigging

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

024 622

NUT, 625-11 1.00 hex .50h stl 2 set screws

2

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . 

29

190 100

HOLDER, brush assembly (consisting of)

3

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

190 103

HOLDER, brush

1

. . . . . . . . . . . . . . . . . . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

190 107

BRUSH SET, contact elect

1

. . . . . . . . . . . . . . . . . . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

190 106

RETAINER, brush holder

1

. . . . . . . . . . . . . . . . . . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

018 606

SPRING, cprsn

5

. . . . . . . . . . . . . . . . . . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

190 105

SPACER, brush holder

2

. . . . . . . . . . . . . . . . . . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

30

FRONT PANEL ASSEMBLY, (Figure 6-2)

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

T1

187 664

TRANSFORMER, main power 200/230/460 (consisting of)

1

. . . 

. . . . 

. . . . . 

. . 

. . . . . . . . . . . . 

32

176 602

COIL, pri/sec 200/230/460 No. 3 bottom

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

33

176 601

COIL, pri/sec 200/230/460 No. 2 center

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

176 600

COIL, pri/sec 200/230/460 No. 1 top

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

T1

187 667

TRANSFORMER, main power 220/400/440 (302 models)

. . . 

. . . . 

. . . . . 

. . 

(consisting of)

1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

32

176 770

COIL, pri/sec 220/380/415 No. 3 bottom

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

33

176 769

COIL, pri/sec 220/380/415 No. 2 center

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

176 767

COIL, pri/sec 220/380/415 No. 1 top

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

T1

187 666

TRANSFORMER, main  power 380/520 (302 models)

. . . 

. . . . 

. . . . . 

. . 

(consisting of)

1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

32

176 666

COIL, pri/sec 380/520 No. 3 bottom

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

176 665

COIL, pri/sec 380/520 No. 2 center

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

176 664

COIL, pri/sec 380/520 No. 1 top

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

T1

187 665

TRANSFORMER, power main 575V (302 model) (consisting of)

1

. . . 

. . . . 

. . . . . 

. . 

. . . . . . . 

32

183 188

COIL, pri/sec 575 No. 3 bottom

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

183 187

COIL, pri/sec 575 No. 2 center

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

183 186

COIL, pri/sec 575 No. 1 top

1

. . . 

. . . . . . . . . . . . . 

. . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

35

187 682

BAR, mtg transformer

1

. . . 

. . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

36

PC1

180 264

CIRCUIT CARD, firing

1

. . . 

. . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

134 201

STAND-OFF SUPPORT, pc card

4

. . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

37

AC2

177 336

REACTOR, (252 model)

1

. . . 

. . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Summary of Contents for CP-252TS

Page 1: ...Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source OM 259 177 743P June 2003 CP 302 and CP 252TS Visit our website at www MillerWelds com...

Page 2: ...ue established in 1929 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 will help you protect yourself against...

Page 3: ...hts 11 2 5 Selecting A Location 12 2 6 Typical MIG Process Connections Using A Constant Speed Wire Feeder 12 2 7 Typical MIG Process Connections Using A Voltage Sensing Wire Feeder 13 2 8 Slope Select...

Page 4: ......

Page 5: ...that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power...

Page 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 7: ...y D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference D High frequency H F can interfere with radio n...

Page 8: ...e 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 Su...

Page 9: ...on d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D Pour ex cuter les branchements d entr e fixer d abord...

Page 10: ...e des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au buta...

Page 11: ...s et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences D Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigat...

Page 12: ...andards 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 Pitts...

Page 13: ...cle 14 44 38 3 34 5 2 8 33 2 7 20 1 9 19 1 6 17 3 1 5 16 5 1 4 14 6 1 1 13 0 0 7 13 1 0 97 12 3 0 68 While idling 2 2 Duty Cycle And Overheating Continuous Welding Duty Cycle is percentage of 10 min u...

Page 14: ...curve1 4 95 SA 180 902 SA 180 901 B 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 Model...

Page 15: ...mensions A A 30 in 762 mm Including lift eye B 23 in 584 mm B C C 31 in 787 mm Including strain relief D 27 1 2 in 699 mm F G H E 3 4 in 19 mm 4 Holes F 21 1 8 in 537 mm G 1 1 8 in 29 mm D H 7 16 in 1...

Page 16: ...378 B 2 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 vehicle Place wo...

Page 17: ...as possible Voltage sensing wire feeders are used with constant current CC or constant voltage CV power sources 14 pin receptacle not re quired If using a CC welding power source without a weld output...

Page 18: ...72 With Pressure Connectors Slide pressure connectors onto the same tap of each coil and secure them Y An unbalanced secondary current can damage the main transformer and cause errat ic weld condition...

Page 19: ...the weld puddle connect to stabilizer Z ending To change inductance proceed as follows 2 Lead 25 3 Stabilizer Z Tap 4 Stabilizer Z Ending 5 Lead 26 To increase inductance connect lead 26 to stabilizer...

Page 20: ...0 100 Duty Cycle 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...

Page 21: ...in 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 Norma...

Page 22: ...inks to match input volt age and label on unit Tighten jumper link nuts to 25 in lb 5 in lb 2 1 200 VOLTS 230 VOLTS 460 VOLTS S 072 135 B L1 L2 L3 L1 L2 L3 L1 L2 L3 3 8 1 2 in 220 VOLTS S 177 581 L1 L...

Page 23: ...tor 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 Y In the dee...

Page 24: ...splays actual welding voltage while welding Y Weld output terminals are energized only when the preset indicator light is Off 4 Voltage Adjustment Control 5 Voltmeter 6 Ammeter 1 2 3 4 5 6 SECTION 4 M...

Page 25: ...ting 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...

Page 26: ...ervice 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...

Page 27: ...OM 259 Page 23 SECTION 5 ELECTRICAL DIAGRAMS 212 993 A Figure 5 1 Circuit Diagram For 250 Ampere Model...

Page 28: ...OM 259 Page 24 212 994 A Figure 5 2 Circuit Diagram For 300 Ampere Models...

Page 29: ...OM 259 Page 25 Notes...

Page 30: ...9 Page 26 SECTION 6 PARTS LIST Figure 6 1 Complete Assembly 801 383 J 1 2 3 4 5 40 6 7 8 9 10 11 12 13 14 15 39 44 43 42 41 Fig 6 3 17 1 36 37 38 19 20 35 34 33 32 31 28 27 26 25 24 23 22 21 29 Fig 6...

Page 31: ...ws 2 29 190 100 HOLDER brush assembly consisting of 3 190 103 HOLDER brush 1 190 107 BRUSH SET contact elect 1 190 106 RETAINER brush holder 1 018 606 SPRING cprsn 5 190 105 SPACER brush holder 2 30 F...

Page 32: ...ard fuses replace 1 44 212 986 INSULATOR cover fuse 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Ref 802 497 2 1 3 4 5 5 2 7 9 10 11 12 14 15 16 17 18 19 20 21 6 8 13 2...

Page 33: ...2 093 995 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 13 176 632 BAFFLE air 1 14 119 005 METER amp DC 50MV 0 400 1 15 118 902 METER volt DC 0 50 1 16 PL1 163 562 LIGHT ind wht lens 115VAC 1 17 PL2 074...

Page 34: ...fier 2 2 087 461 HEAT SINK 2 3 TP1 165 670 THERMOSTAT NC open 300F 1 4 024 241 ANGLE mtg term 2 5 PLG1 158 720 CONNECTOR SOCKETS 1 6 SCR1 3 180 456 THYRISTOR SCR 175 A30 3 7 195 790 ASSEMBLY BRACKET r...

Page 35: ...ols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles cont...

Page 36: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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