Assessments - 4, GPA: 4.5
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Duty Cycle And Overheating Continuous Welding Duty Cycle is percentage of 10 minutes 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 Overheating 0 15 A/V OR Reduce Duty CycleMinutes duty1 4/95 / Ref. SA-177 714-B CP302 CP252TS OM-259 Page 9 2-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. A. 250 Ampere Models B. 300 Ampere Models CP302 MAX CP302 MIN va_curve1 4/95 – SA-180 902 / SA-180 901-B OM-259 Page 10 OM-259 Page 11 2-4. Dimensions And Weights C Dimensions E D Height 27-1/4 in (692 mm) 4 Holes Width 22-1/4 in (565 mm) Depth 28-1/4 in (717 mm) A 27-1/2 in (698 mm) A B 3/4 in (19 mm) C 21-1/8 in (537 mm) D 1-1/8 in (29 mm) E 7/16 in (11 mm) Dia Weight ST-801 530 B 320 lb (145 kg) 2-5. Selecting A Location 1 Rating Label Use rating label to determine input power needs. Label located under front access door. 2 Line Disconnect Device Locate unit near correct input power supply. Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 2 18 in (460 mm) 18 in (460 mm) Movement Location And Airflow 1 Do not move or operate unit where it could tip. Tipping Ref. ST-801 378-B 2-6. Typical MIG Process Connections Using A Constant Speed Wire Feeder 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. Constant speed wire feeders are used with constant voltage (CV) power sources having a 14-pin receptacle. For flux cored welding (FCAW), contact welding wire manufacture for polarity recommendations. Gun Workpiece Electrode Lead Work Lead 14-Pin Interconnecting Cord Gas Shielding Gas Regulator/ Flowmeter Work Clamp mig 9/99 / Ref. ST-800 357-A Constant Voltage (CV) Welding Power SourceConstant Speed Wire Feeder (When Required) 2-7. Typical MIG Process Connections Using A Voltage-Sensing Wire Feeder 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 required). If using a CC welding power source without a weld output contactor, use optional secondary contactor. For GMAW, use optional gas valve. Voltage Sensing Wire Feeder Constant Current (CC) Or Constant Voltage (CV) Power Source Work Lead Electrode LeadWorkpiece Work Clamp Voltage Sensing Clamp Gun 802 488 OM-259 Page 12 OM-259 Page 13 2-8. Slope Selection (250 Ampere Model) Ref. ST-801 518-A 1 Slope Connection Label 2 Tapped Reactor AC-Z And Slope Coils Tapped reactor AC-Z is factory connected to slope tap 8 which is suitable 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 number. 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 erratic weld conditions. Be sure leads 70, 71 and 72 are connected 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 connections made in Section A as follows: RC3 – 300A (Used With 300A Models Only) RC4 for 4 turns RC5 for 6 turns RC6 for 8 turns RC7 for 10 turns. Reinstall right side panel. 1 2 3 1/2 in 3/8 in 4 7 6 5 S-177 763-B 8 6 4 8 6 4 8 6 4 0 0 0 SLOPE TURNS TAP SLOPE CONNECTIONS IMPORTANT: Be sure connections are clean before reconnecting tap. IMPORTANT: Move friction lug on PC1 to correct tab to insure proper operation of voltmeter preset. 10 10 10 2-9. Inductance Selection (300 Ampere Models) 1 2 3 4 5 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 increase inductance and wet out 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 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 suitable for some mild steel applications. 7 Typical Weld Bead Using The End High Stabili...
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