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Miller Electric CST 250 VRD manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.MillerWelds.com Pro cesses Descrip ti on Stick (SMAW ) W elding OM -220 812B March 2005 Arc Welding Power Source TIG (GT A W ) W elding CST 250 VRD International[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-220 812 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means W arning! Wa[...]

  • Page 6

    OM-220 812 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin.  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 [...]

  • Page 7

    OM-220 812 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard.  Do not install or place unit on, over , or near combustible surfaces.  Do not install unit near flammables.  Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this[...]

  • Page 8

    OM-220 812 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W[...]

  • Page 9

    OM-220 812 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives.  Identifie un message de sécurité particulier .  Signifie[...]

  • Page 10

    OM-220 812 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent cau- ser des brûlures oculaires et cuta- nées.  Porter un masque de soud[...]

  • Page 11

    OM-220 812 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION  Ne pas placer l’appareil sur une surface inflam- mable, ni au − dessus ou à proximité d’elle.  Ne pas installer l’appareil à proximité de produits inflammables.  Ne [...]

  • Page 12

    OM-220 812 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443 − 9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and [...]

  • Page 13

    OM-220 812 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications W elding Mode Input Power Rated Output W elding Amperage Range Maximum Open-Circuit V oltage Amperes Input At Rated Load Output, 50/60 Hz KV A KW Dimensions Net W eight Range V oltage 220 400 440 KV A KW Dimensions W e i g ht 3-Phase 250 A @ 30 VDC, 50 % Duty Cycle 5-250 A 30 VDC 32[...]

  • Page 14

    OM-220 812 Page 10 3-3. Stick (SMA W) V olt-Ampere Curves V olt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. DC VOL TS DC AMPS XX10 STICK V A CURVES 0 50 100 150 200 250 300 350 400 0 10 20 30 40 50 60 70 80 90 30A SOFT 30A STIFF 250A SOF[...]

  • Page 15

    OM-220 812 Page 1 1 3-4. TIG (GT A W) V olt-Ampere Curve V olt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. LIFT ARC TIG (GT A W) DC AMPS DC VOL TS 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35[...]

  • Page 16

    OM-220 812 Page 12 3-5. Selecting A Location 1 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 51 1 or CEC Section 20. Location And Airflow 1 18 in (460 mm) 18 in (460 mm) 803 080 18 in (457 mm) 13-1/2 in (343 mm) 7-1/2 i[...]

  • Page 17

    OM-220 812 Page 13 3-6. W eld Output T erminals And Selecting Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals Welding Amperes*** 10 − 60% Duty Cycle 60 − 100% Duty Cyc[...]

  • Page 18

    OM-220 812 Page 14 3-7. TIG Lift-Arc t DCEN (Direct Current Electrode Negative) Connections Ref. 802 888 / Ref. 803 080 1 Positive (+) W eld Output T erminal Connect work lead to positive weld output terminal. 2 Negative ( − ) W eld Output T erminal Connect TIG torch to negative weld output terminal. 3 Gas Cylinder 4 Cylinder V alve Open valve sl[...]

  • Page 19

    OM-220 812 Page 15 3-8. Stick DCEP (Direct Current Electrode Positive) Connections Ref. 802 888 / Ref. 803 080 1 Negative ( − ) W eld Output T erminal Connect work lead to negative weld output terminal. 2 Positive (+) Weld Output T erminal Connect electrode holder to positive weld output terminal. 1 2 3-9. Electrical Service Guide  CAUTION: IN[...]

  • Page 20

    OM-220 812 Page 16 3-10. Selecting 220 V olts AC Single/Three Phase Input V oltage 803 079 / 803 077  T urn Off welding power source, and disconnect input power before proceeding. Check input voltage available at site. 1 V oltage Selection V iew Window The input voltage that the power source is linked for appears in the V oltage Selection V iew [...]

  • Page 21

    OM-220 812 Page 17 3-1 1. Selecting 400 - 440 V olts AC Three Phase Input V oltage 803 079 / 803 078  T urn Off welding power source, and disconnect input power before proceeding. Check input voltage available at site. 1 V oltage Selection V iew Window The input voltage that the power source is linked for appears in the V oltage Selection V iew [...]

  • Page 22

    OM-220 812 Page 18  Disconnect and lockout/tag- out input power before connecting input conduc- tors from unit.  Have only qualified persons make this installation. See rating label on unit and check input voltage available at site. 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 3-9. For three-phase operation:  Alway[...]

  • Page 23

    OM-220 812 Page 19 SECTION 4 − OPERA TION 4-1. Controls 220 685-A / 803 080 NOTE: Green on nameplate indicates a TIG function, Gray indicates a Stick function. 1 Power Switch Use switch to turn unit and indicator light On/Of f. 2 Output Indicator Light When unit is first energized this indicator light flashes several times and then illuminates co[...]

  • Page 24

    OM-220 812 Page 20 4-2. Process Select Control 1 Process Select Control Rotate knob to select desired process. Lift-Arc  TIG - Normal open-circuit voltage is not present between the electrode and workpiece. A solid-state contactor does not energize until after the electrode touches the workpiece, preventing overheating, sticking, or contaminatin[...]

  • Page 25

    OM-220 812 Page 21 4-3. Stick Start Procedure − Scratch Start T echnique With Stick selected, start arc as follows: 1 Electrode 2 W orkpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to [...]

  • Page 26

    OM-220 812 Page 22 4-5. Amp Adjust Control 1 AMP ADJUST (Amperage Control) Rotate knob clockwise to increase amperage (5-250 amps). 1 4-6. Remote 14 Receptacle Information This unit automatically senses when a remote control is connected to the remote 14 receptacle. After connecting a remote control, the unit will automatically adjust output contro[...]

  • Page 27

    OM-220 812 Page 23 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance  Disconnect power before maintaining.  Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Replace Damaged Gas Hose 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Blow out insi[...]

  • Page 28

    OM-220 812 Page 24 5-3. T roubleshooting 1 2 1 Output LED (Blue) 2 High T emperature LED (Y ellow) 803 080 T rouble Possible Causes Remedy No weld output; unit completely inoperative. Line disconnect switch open. Place line disconnect switch in On position (see Section 3-12 ). Blown line fuse(s). Check and replace line fuse(s), if necessary , or re[...]

  • Page 29

    OM-220 812 Page 25 T rouble Remedy Possible Causes Erratic or improper weld output. W eld cable too small or defective. Use proper size and type of weld cable (see Section 3-6). Dirty or loose connections. Clean and tighten all weld connections (see Section 3-6). W andering arc Improper size tungsten. Use proper size tungsten (see Section 7). W orn[...]

  • Page 30

    OM-220 812 Page 26 SECTION 6 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram 206 171-D[...]

  • Page 31

    OM-220 812 Page 27 SECTION 7 − SELECTING AND PREP ARING TUNGSTEN ELECTRODE gtaw 7/97 For additional information, see your distributor for a handbook on the Gas T ungs ten Arc Welding (GT AW ) proces s. Wear clean gloves to prevent contamination of tungsten electrode. NOTE 7-1. Selecting T ungsten Electrode Amperage Range - Gas T ype ♦ - Polarit[...]

  • Page 32

    OM-220 812 Page 28 7-3. Preparing T ungsten For AC Or DC Electrode Negative (DCEN) Welding Ref. S-0161 / Ref. S-0162 1 T ungsten Electrode 2 T apered End Grind end of tungsten on fine grit, hard abrasive wheel before weld- ing. Do not use wheel for other jobs or tungsten can become contami- nated causing lower weld quality . 3 Ideal Tungsten Prepar[...]

  • Page 33

    OM-220 812 Page 29 Notes[...]

  • Page 34

    OM-220 812 Page 30 SECTION 8 − P ARTS LIST  Hardware is common and not available unless listed. 803 157-B 8 12 13 20 21 25 23 7 2 4 22 3 24 10 5 1 9 6 15 19 14 14 15 18 17 19 28 26 11 27 16 Figure 8-1. Main Assembly[...]

  • Page 35

    OM-220 812 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 205758 P ANEL,FRONT W/CMPNT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 205780 P ANEL,REAR W/CMPNT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-220 812 Page 32  Hardware is common and not available unless listed. 803 158 14 9 13 12 15 3 17 4 2 18 1 19 8 20 4 6 5 22 21 10 16 11 7 7 23 Figure 8-2. Panel, Front w/Components Figure 8-2. Panel, Front w/Components Diagram marking Item No. Part No. Description Quantity 1 194242 P ANEL,FRONT/REAR 1 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 37

    OM-220 812 Page 33  Hardware is common and not available unless listed. 803 161-B 7 6 1 2 7 3 4 5 Figure 8-3. Panel, Rear w/Components Description Part No. Dia. Mkgs. Item No. Figure 8-3. Panel, Rear w/Components Quantity 1 194242 P ANEL,FRONT/REAR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 38

    OM-220 812 Page 34  Hardware is common and not available unless listed. 803 163-B 13 3 1 10 9 11 12 14 8 7 8 2 5 4 6 8 16 15 Figure 8-4. Magnetics Subassembly Description Part No. Dia. Mkgs. Item No. Figure 8-4. Magnetics Subassembly Quantity 1 206063 P ANEL,PLENUM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 39

    OM-220 812 Page 35  Hardware is common and not available unless listed. 803 159-C 4 8 1 9 6 7 3 2 12 13 11 10 12 5 13 Figure 8-5. Heat Sink Assembly , Output Diode Description Part No. Dia. Mkgs. Item No. Figure 8-5. Heat Sink Assembly , Output Diode Quantity 1 205916 HEA T SINK,DIODE OUTPUT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    OM-220 812 Page 36  Hardware is common and not available unless listed. 803 160 2 3 1 5 4 8 7 6 Figure 8-6. Base Assembly Description Part No. Dia. Mkgs. Item No. Figure 8-6. Base Assembly Quantity 1 206089 BASE, 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 41

    OM-220 812 Page 37  Hardware is common and not available unless listed. Ref. 803 162 1 2 3 Figure 8-7. Heat Sink Assembly , Input Description Part No. Dia. Mkgs. Item No. Figure 8-7. Heat Sink Assembly , Input Quantity 1 205915 HEA T SINK,IGBT/INPUT RECTIFIER MODULE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 42

    Notes[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou 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 o[...]

  • Page 44

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West Spenc er S treet Applet on, W I 54914 USA International He adquarters − US A USA P hone: 920-735-4505 Aut o-At tended USA & C anada F A X: 920-735-4134 Int ernat ional FAX: 920-735-4125 European Headqua rters − United K[...]