Miller Electric CST 250 VRD User Manual

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OM-220 812B

March 2005

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source

CST 250 VRD

International

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.

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 potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

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. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Stick (SMAW) Volt-Ampere Curves 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. TIG (GTAW) Volt-Ampere Curve 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Selecting A Location 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Weld Output Terminals And Selecting Cable Sizes* 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections 14 . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Stick DCEP (Direct Current Electrode Positive) Connections 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Electrical Service Guide 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Selecting 220 Volts AC Single/Three Phase Input Voltage 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Selecting 400 - 440 Volts AC Three Phase Input Voltage 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Connecting Input Power 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Process Select Control 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Stick Start Procedure − Scratch Start Technique 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Lift-ArcE Start Procedure 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Amp Adjust Control 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Remote 14 Receptacle Information 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Fan-On-Demand 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Rack Mounting 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Blowing Out Inside Of Unit 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − SELECTING AND PREPARING

TUNGSTEN ELECTRODE 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Selecting Tungsten Electrode 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Safety Information About Tungsten 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding 28 . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

som _8/03

 Marks a special safety message.

 Means “Note”; 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 1-5. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and

repair this unit.

 During operation, keep everybody, especially children, away.

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

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.

 Do not touch live electrical parts.  Wear dry, hole-free insulating gloves and body protection.  Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

 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 welding process.  If AC output is required, use remote output control if present on

unit.

 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).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 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.

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 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.

power circuit and machine internal circuits are also

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.

 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

 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.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 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.

 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

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

 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.

 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-220 812 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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.

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

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.

 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.

 Watch for fire, and keep a fire extinguisher nearby.  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.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

 Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.  Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.  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.

 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 − 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 cylinder 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.

OM-220 812 Page 2

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 unit.

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

 Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

 Keep away from moving parts such as fans.  Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

 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 installation.

 If notified by the FCC about interference, stop using the

equipment at 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.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

 Keep away from moving parts.  Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

1-4. California Proposition 65 Warnings

 Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

 Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

 Be sure all 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.

For Gasoline Engines:  Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:  Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other reproductive harm.

OM-220 812 Page 3

1-5. 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 Cutting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, 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).

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, website: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. 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 electromagnetic 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 committee’s judgment, has not demonstrated that exposure to powerfrequency 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:

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, 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 Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent 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. Keep cables 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 operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-220 812 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT

UTILISATION

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.

Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-

 Identifie un message de sécurité particulier.

 Signifie « NOTA » ; n’est pas relatif à la sécurité.

2-2. Dangers relatifs au soudage à l’arc

lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

 Les symboles ci-après sont utilisés tout au long du présent

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 mentionnées afin d’éviter tout danger. Les consignes de sécurité énoncées ci-après ne font que résumer le contenu des normes de sécurité mentionnées à la section 2-4. Lire et respecter toutes ces normes.

 L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

 Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,

en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES peuvent être mortelles.

Un simple contact avec des pièces sous tension peut causer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension

d’entrée et les circuits internes de l’appareil sont également sous tension. En soudage semi−automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal mis à la terre présente un danger.

 Ne jamais toucher aux pièces électriques sous tension.  Porter des gants et des vêtements de protection secs et exempts de

trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empêcher tout contact physique avec la pièce ou la terre.

 Ne pas se servir d’une source de courant alternatif dans les zones humi-

des, les endroits confinés ou là où on risque de tomber.

 Ne se servir d’une source de courant alternatif QUE si le procédé de souda-

ge l’exige.

 Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-

vir de la fonction de télécommande si l’appareil en est équipé.

 Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).

 Installer et mettre à la terre correctement l’appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

 Pour exécuter les branchements d’entrée, fixer d’abord le conducteur

de mise à la terre adéquat et contre−vérifier les connexions.

 Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est

ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.  Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou

mal épissés.

 Ne pas s’enrouler les câbles autour du corps.  Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

 Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode d’une autre machine.

dès que l’appareil est en fonctionnement. Le circuit

 N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−

champ les pièces endommagées. Entretenir l’appareil conformément au présent manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.  Maintenir solidement en place tous les panneaux et capots.  Fixer le câble de retour de façon à obtenir un bon contact métal sur

métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

 Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un

même terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

 Arrêter les convertisseurs, débrancher le courant électrique et dé-

charger les condensateurs d’alimentation selon les instructions énoncées à la section Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz dont l’inhalation peut être dangereuse pour la santé.

 Se tenir à distance des fumées et ne pas les inhaler.  À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est insuffisante, utiliser un respirateur à adduction

d’air agréé.

 Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

 Ne travailler dans un espace clos que s’il est bien ventilé ou porter un

respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent se substituer à l’air, abaisser la teneur en oxygène et causer des lésions ou des accidents mortels. S’assurer que l’air est respirable.

 Ne pas souder à proximité d’opérations de dégraissage, de nettoyage

ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

 Ne pas souder de métaux munis d’un revêtement, tels que la tôle

d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.

OM-220 812 Page 5

LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.

Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage.

 Porter un masque de soudage muni d’un filtre de la nuance adéquate

pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).

 Porter des lunettes de sécurité à écrans latéraux sous le masque.  Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat

éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder l’arc.

 Porter des vêtements de protection en matière durable et ignifuge

(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées

pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

 Se protéger et protéger les tiers de la projection d’étincelles et de mé-

tal chaud.

 Ne pas souder à un endroit où des étincelles peuvent tomber sur des

substances inflammables.

 Placer toutes les substances inflammables à une distance de 10,7 m

de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.

 Des étincelles et des matières en fusion peuvent facilement passer

même par des fissures et des ouvertures de petites dimensions.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

 Le soudage effectué sur un plafond, un plancher, une paroi ou une

cloison peut déclencher un incendie de l’autre côté.

 Ne pas souder des récipients fermés tels que des réservoirs, des fûts

ou des conduites, à moins qu’ils n’aient été préparés conformément à l’AWS F4.1 (voir les normes de sécurité).

 Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

 En cas de non utilisation, enlever la baguette d’électrode du porte−

électrode ou couper le fil au raz du tube−contact.

 Porter des vêtements de protection exempts d’huile tels que des

gants en cuir, une chemise en tissu épais, des pantalons sans revers, des chaussures montantes et un masque.

 Avant de souder, retirer tout produit combustible de ses poches, tel

qu’un briquet au butane ou des allumettes.

de l’arc de soudure. La projection d’étincelles, les

LES PARTICULES PROJETÉES peuvent blesser les yeux.

 Le soudage, le burinage, le passage de la pièce à

la brosse métallique et le meulage provoquent

ques. Pendant leur refroidissement, les soudures risquent de projeter du laitier.

 Porter des lunettes de sécurité à écrans latéraux agréés, même sous le

masque de soudage.

l’émission d’étincelles et de particules métalli-

LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même la mort.

 Couper l’alimentation en gaz protecteur en cas de

non utilisation.

 Veiller toujours à bien ventiler les espaces confinés ou porter un respira-

teur à adduction d’air agréé.

LES PIÈCES CHAUDES peuvent causer des brûlures graves.

 Ne pas toucher les pièces chaudes à main nue.  Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimulateurs cardiaques.

 Les personnes qui portent un stimulateur cardiaque

doivent se tenir à distance.

 Ils doivent consulter leur médecin avant de s’appro-

cher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit de certains processus et équipements peut affecter l’ouïe.

 Porter des protecteurs d’oreille agréés si le niveau

sonore est trop élevé.

Les BOUTEILLES endommagées peuvent exploser.

Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommagée peut exploser. Comme les bouteilles de gaz font

manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé de la chaleur excessive, des

chocs mécaniques, du laitier, des flammes nues, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire

ou dans un porte−bouteilles pour les empêcher de tomber ou de se renverser.

 Tenir les bouteilles éloignées des circuits de soudage ou autres cir-

cuits électriques.

 Ne jamais poser une torche de soudage sur une bouteille de gaz.  Ne jamais mettre une électrode de soudage en contact avec une bou-

teille de gaz.

 Ne jamais souder une bouteille contenant du gaz sous pression − elle

risquerait d’exploser.

 N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords adéquats pour l’application envisagée ; les maintenir en bon état, ainsi que les pièces connexes.

 Détourner la tête 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

 Lire et suivre les instructions concernant les bouteilles de gaz compri-

mé, les équipements associés et les publications P−1 de la CGA, mentionnées dans les normes de sécurité.

normalement partie du procédé de soudage, les

OM-220 812 Page 6

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de

l’appareil.

Risque D’INCENDIE OU D’EXPLOSION

 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 pas surcharger l’installation électrique − s’assurer que l’alimen-

tation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

 N’utiliser que l’anneau de levage pour lever l’ap-

pareil. NE PAS utiliser le chariot, les bouteilles de gaz ou tout autre accessoire.

 Utiliser un engin de capacité adéquate pour lever

 Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que

les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

l’appareil.

L’EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L’ÉQUIPEMENT.

 Prévoir une période de refroidissement ; respec-

ter le cycle opératoire nominal.

 Réduire le courant ou le cycle opératoire avant de

 Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

reprendre le soudage.

LES ORGANES MOBILES peuvent causer des blessures.

 Se tenir à l’écart des organes mobiles comme les

ventilateurs.

 Maintenir fermés et bien fixés les portes,

panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des interférences.

 Le rayonnement haute fréquence peut causer

des interférences avec les équipements de radionavigation et de communication, les services de sécurité et les ordinateurs.

 Ne demander qu’à des personnes qualifiées familiarisées avec les

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences causées par l’installation.

 Si la Federal Communications Commission signale des interféren-

ces, arrêter immédiatement l’appareil.

 Faire régulièrement contrôler et entretenir l’installation.  Maintenir soigneusement fermés les panneaux et les portes des sour-

ces de haute fréquence, maintenir le jeu d’éclatement au réglage adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.

LE SOUDAGE À L’ARC peut causer des interférences.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Mettre un bracelet antistatique AVANT de mani-

puler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimés.

LES PIÈCES MOBILES peuvent causer des blessures.

 Se tenir à l’écart des pièces mobiles.  Se tenir à l’écart des points de coincement tels

que les dévidoirs.

LES FILS DE SOUDAGE peuvent causer des blessures.

 Ne pas appuyer sur la gâchette avant d’en avoir

reçu l’instruction.

 Ne pas diriger le pistolet vers soi, vers d’autres

personnes ou vers toute pièce mécanique en engageant le fil de soudage.

 L’énergie électromagnétique peut causer des

interférences avec l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit compati-

ble au point de vue électromagnétique.

 Pour réduire la possibilité d’interférence, maintenir les câbles de sou-

dage aussi courts que possible, les grouper, et les poser aussi bas que possible (par ex. : à terre).

 Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

 Veiller à ce que le poste de soudage soit posé et mis à la terre confor-

mément au présent manuel.

 En cas d’interférences après exécution des directives précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

 Porteurs de stimulateur cardiaque, restez à dis-

tance.

 Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

OM-220 812 Page 7

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding 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 Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (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 (téléphone : (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 (téléphone : (703) 412−0900, site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.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 (téléphone : (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 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site Web : www.osha.gov).

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.

OM-220 812 Page 8

3-1. Specifications

KVAKWDimensions

Weight

3-Ph

0 A

30 VDC

Stick

W: 7 1/2 in

40 lb

1-Ph

200 A

30 VDC

SECTION 3 − INSTALLATION

Welding

Mode

Stick

(SMAW)

Input

Power

ase

Rated

Output

250 A @ 30 VDC,

50 % Duty

Cycle

200 A @ 28 VDC,

100 %

Duty Cycle

200 A @ 28 VDC,

50 % Duty

Cycle

150 A @ 26 VDC,

100 %

Duty Cycle

Welding

Amperage

Range Voltage

5-25

Maximum

Open-Circuit

3-2. Duty Cycle And Overheating

Amperes Input At Rated Load

Output, 50/60 Hz

220 400 440

32.1 18.2 16.4 12.3 8.7

24.2 14.4 12.6 9.9 6.5

42.6 n/a n/a 10.0 6.6

33.6 n/a n/a 7.4 5.7

KVA KW Dimensions

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

 Exceeding duty cycle can

Net

H: 13-1/2 in

(343 mm)

W: 7-1/2 in

(191 mm)

D: 18 in (457

mm)

damage unit and void warranty.

40 lb

(18.2 kg)

200 A @ 50% Duty Cycle For Single Phase Operation

Overheating

Minutes

206 173

250 A @ 50% Duty Cycle For 3 Phase Operation

5 Minutes Welding 5 Minutes Resting5 Minutes Welding 5 Minutes Resting

A or V

Reduce Duty Cycle

OM-220 812 Page 9

3-3. Stick (SMAW) Volt-Ampere Curves

XX10 STICK VA CURVES

DC VOLTS

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.

0 50 100 150 200 250 300 350 400

30A SOFT 30A STIFF 250A SOFT 250A STIFF

DC AMPS

XX18 STICK VA CURVES

DC VOLTS

30A SOFT 30A STIFF 250A SOFT 250A STIFF

0 50 100 150 200 250 300 350

DC AMPS

OM-220 812 Page 10

3-4. TIG (GTAW) Volt-Ampere Curve

LIFT ARC TIG (GTAW)

DC VOLTS

0 50 100 150 200 250 300

DC AMPS

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.

OM-220 812 Page 11

3-5. Selecting A Location

Dimensions And Weight

40 lb (18.2 kg) - with power cord

7-1/2 in

(191 mm)

18 in

(457 mm)

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 511 or CEC Section 20.

13-1/2 in

(343 mm)

Location And Airflow

18 in

(460 mm)

18 in

(460 mm)

OM-220 812 Page 12

803 080

3-6. Weld Output Terminals And Selecting Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding

100 ft (30 m) Or Less

Weld Output

Terminals

−

Output Receptacles

* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger

cable.

**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.

( ) = mm2 for metric use

***Select weld cable size for pulsing application at peak amperage value. S-0007-E−803 080

Welding

Amperes***

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 − 100% Duty Cycle

300 ft

(90 m)

2 ea. 2/0

(2x70)

350 ft

(105 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

400 ft

(120 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

OM-220 812 Page 13

3-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections

1 Positive (+) Weld Output

Terminal

Connect work lead to positive weld output terminal.

2 Negative (−) Weld Output

Terminal

Connect TIG torch to negative weld output terminal.

3 Gas Cylinder 4 Cylinder Valve Open valve slightly so gas flow

blows dirt from valve. Close valve. 5 Regulator/Flowmeter 6 Flow Adjust Typical flow rate is 15 cubic feet per

hour (7.1 liters per minute). Connect torch gas hose to

regulator/flowmeter. 7 Gas Valve Valve controls gas preflow and

postflow. Open valve on torch just before welding.

Tools Needed:

11/16 in, 1-1/8 in, (21 mm)

Ref. 802 888 / Ref. 803 080

OM-220 812 Page 14

3-8. Stick DCEP (Direct Current Electrode Positive) Connections

1 Negative (−) Weld Output

Terminal

Connect work lead to negative weld output terminal.

2 Positive (+) Weld Output

Terminal

Connect electrode holder to positive weld output terminal.

Ref. 802 888 / Ref. 803 080

3-9. Electrical Service Guide

 CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding

power source requires a CONTINUOUS supply of 50/60 Hz power at +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

NOTE

Input Voltage 220 220 400 440

Input Amperes At Rated Output 45 32 18 16

Max Recommended Standard Fuse Rating In Amperes

Normal Operating 3 70 50 25 25

Actual input voltage cannot exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, no output is available.

Time-Delay

50/60 Hz Single-Phase,

50% Duty Cycle

50 40 20 20

50/60 Hz Three-Phase,

50% Duty Cycle

Min Input Conductor Size In AWG/Kcmil 8 10 14 14

Max Recommended Input Conductor Length In Feet (Meters) 129 (39) 132 (40) 174 (53) 210 (64)

Min Grounding Conductor Size In AWG/Kcmil 8 10 14 14

Reference: 2002 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse. 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).

 Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

OM-220 812 Page 15

3-10. Selecting 220 Volts AC Single/Three Phase Input Voltage

 Turn Off welding power

source, and disconnect input power before proceeding.

Check input voltage available at site.

1 Voltage Selection View

Window

The input voltage that the power source is linked for appears in the Voltage Selection View Window.

Check voltage selected in unit. Changing selection is only necessary if selected value does not match available input voltage.

To change relinking board position, remove top cover and left side panel.

2 Relinking Board 3 Terminal Screws Loosen terminal screws. 4 Relinking Board (Connection

For 220 VAC Single/Three Phase Input Power)

Slide relinking board off connected terminals, move relinking board to correct input voltage terminals, and secure relinking board.

Tools Needed:

OM-220 812 Page 16

5/16 in

 Be sure to tighten all four screws

securing relinking board in place.

803 079 / 803 077

3-11. Selecting 400 - 440 Volts AC Three Phase Input Voltage

 Turn Off welding power

source, and disconnect input power before proceeding.

Check input voltage available at site.

1 Voltage Selection View

Window

The input voltage that the power source is linked for appears in the Voltage Selection View Window.

Check voltage selected in unit. Changing selection is only necessary if selected value does not match available input voltage.

To change relinking board position, remove top cover and left side panel.

2 Relinking Board 3 Unused Terminal 4 Terminal Screws Loosen terminal screws. 5 Relinking Board (Connection

For 400 - 440 VAC Input Power)

Slide relinking board off connected terminals, move relinking board to correct input voltage terminals, and secure relinking board.

Tools Needed:

5/16 in

 Be sure to tighten all four screws. Three

screws securing relinking board in place.

803 079 / 803 078

OM-220 812 Page 17

3-12. Connecting Input Power

L1 L2

Green Or

Green/Yellow

 Always connect grounding

conductor first

= GND/PE

Green Or

Green/Yellow

 Disconnect and lockout/tag-

out input power before connecting input conductors 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:

 Always connect green or

green/yellow wire to supply

grounding terminal, never to

a line terminal.

Connect black, white, and red wires (L1, L2, L3) to line terminals.

For single-phase operation:

 Always connect green or

green/yellow wire to supply

grounding terminal, never to

a line terminal.

3 Black And White Input

Conductor 4 Red Input Conductor 5 Insulation Sleeving 6 Electrical Tape Insulate and isolate red conductor

as shown.

Green or

Green/Yellow

input_2 3/96 - 803 080

OM-220 812 Page 18

4-1. Controls

SECTION 4 − OPERATION

3245

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/Off.

CST 250 VRD

2 Output Indicator Light When unit is first energized this indicator

light flashes several times and then illuminates continuously. When unit is shut down, the indicator light flashes several times and the cooling fan will run briefly, then both will turn off completely.

3 Process Select Control See Section 4-2.

4 Amp Adjust Control See Section 4-5. 5 High Temperature Shutdown Light When unit is first energized this indicator

light illuminates for approximately 1 second to provide visual confirmation that the light is functioning properly (see Section 3-2).

6 Remote 14 Receptacle

220 685-A / 803 080

OM-220 812 Page 19

4-2. Process Select Control

RECOMMENDED PROCESS

SELECTIONS VS ELECTRODE TYPE

ELECTRODE

TYPE

EXXX1 EXXX2

EXXX3 EXXX4 EXXX5 EXXX6 EXXX7 EXXX8

STAINLESS

SUGGESTED PROCESS

SETTING

EXX10 EXX10

EXX18 EXX18 EXX18 EXX18 EXX18 EXX18 EXX18

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 contaminating the electrode (see Section 4-4). Make connections according to Section 3-7.

Stick E XX18 Soft - This setting provides a lower dig/arc force setting for smooth weld perfromance. A stable weld puddle with little arc “snap” gives excellent weld bead appearance with minimal spatter. Make connections according to Section 3-8.

Stick E XX18 Stiff - This setting provides a higher dig/arc force that gives a slightly more fluid weld puddle, more arc “snap”, and reduces the potential for electrode sticking at shorter arc lengths. Make connections according to Section 3-8.

Stick E XX10 Soft - This setting provides lower dig/arc force for open root vertical up joints or joints that do not require additional current for fit up inconsistencies. Make connections according to Section 3-8.

Stick E XX10 Stiff - This setting provides a higher dig/arc force for open root vertical down joints where additional current is needed to compensate for tight joint fit up without the need to increase overall welding current. Make connections according to Section 3-8.

OM-220 812 Page 20

4-3. Stick Start Procedure − Scratch Start Technique

4-4. Lift-Arc™ Start Procedure

Lift-Arc Start Method

“Touch”

1 − 2

Seconds

With Stick selected, start arc as follows:

1 Electrode 2 Workpiece 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 free it.

Normal open-circuit voltage is not present before electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Lift-Arc Start

With Lift-Arc selected, start arc as follows:

1 TIG Electrode 2 Workpiece Turn gas on. Touch tungsten

electrode to workpiece at weld start point. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted.

Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Application:

Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.

Do NOT Strike Like A Match!

OM-220 812 Page 21

4-5. Amp Adjust Control

15 VOLTS DC

1 AMP ADJUST (Amperage

Control)

Rotate knob clockwise to increase amperage (5-250 amps).

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 control to a primary/secondary configuration. In this configuration, the AMP ADJUST control on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range adjustment of 0 to 100% based on the AMP ADJUST control setting.

15 VOLTS D

REMOTE

Socket* Socket Information

A 15 volts dc (not functional).

B Contact closure to A completes 15 volts dc

contactor control circuit (not functional).

C Output to remote control; 0 to +10 volts dc.

D Remote control circuit common.

OUTPUT

*The remaining sockets are not used.

803 080

CONTROL

GND

E 0 to +10 volts dc input command signal from

remote control.

K Chassis common.

4-7. Fan-On-Demand

This unit is equipped with Fan-On-Demand. The fan operates only when necessary to cool internal components. At power down, the fan will operate for a short period of time while the output indicator light is flashing.

4-8. Rack Mounting

This unit is capable of being rack mounted [see rack Owner’s Manual, OM-2238 (208 107)].

OM-220 812 Page 22

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.

3 Months

Repair Or Replace Cracked Cables And Cords

6 Months

 Do not remove case when

blowing out inside of unit (see Section 5-2) .

Blow out inside. During heavy service clean monthly.

5-2. Blowing Out Inside Of Unit

Replace Damaged Gas Hose

 Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow through front and back louvers as shown.

803 080

OM-220 812 Page 23

5-3. Troubleshooting

Blue LED flashes

yellow LED off

Trouble Possible Causes Remedy

No weld output; unit completely inoperative.

1 Output LED (Blue) 2 High Temperature LED

(Yellow)

803 080

Line disconnect switch open. Place line disconnect switch in On position (see Section

3-12).

No weld output.

continuously, yellow

LED off.

No weld output. Blue LED flashes 4 times repeatedly, yellow LED off.

No weld output. Blue LED flashes 5 times repeatedly, yellow LED off.

Low weld output. Blue LED flashes 2 times repeatedly,

No weld output. Blue LED flashes 3 times repeatedly, yellow LED off.

Blown line fuse(s). Check and replace line fuse(s), if necessary, or reset

Improper input power connections. Check for proper input power connections (see Section

Line voltage too high or too low. Line voltage must be within ±10%.

Unit not linked correctly. Check line voltage and link unit accordingly.

Unit needs to be reset. Cycle power switch off and back on again. If problem is not

Voltage in excess of 100 V from an external source across output studs.

Short circuit across output studs. Check and correct any short circuit conditions.

Single phase rating exceeded (output foldback due to excessive input current).

High output VA coupled with a low 230 voltage line (output foldback due to excessive input current).

Remote trigger left on. Turn off remote trigger, wait approximately 5 seconds, and

circuit breaker (see Section 3-12).

3-12).

corrected, contact nearest Factory Authorized Service Agent.

Check and correct any external voltage sources.

Reduce output to 200 amperes or less.

Check line voltage and weld settings.

restart operation.

No weld output. Blue LED flashes 6 times repeatedly, yellow LED off.

No weld output. Blue LED off, yellow LED on.

No weld output. Blue LED off, yellow LED flashes continuously.

Fan not operating. Blocked fan blade. Check and remove anything blocking fan blade movement.

OM-220 812 Page 24

Internal component failure. Contact nearest Factory Authorized Service Agent.

Unit overheated. Allow unit to cool.

Thermistor failure. Have Factory Authorized Service Agent check thermistor.

Fan failure. Have Factory Authorized Service Agent check fan motor.

Trouble RemedyPossible Causes

Erratic or improper weld output. Weld 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).

Wandering arc

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

Improper size tungsten.

Worn or defective tungsten.

Shielding gas flow too high.

Shielding gas blown away from weld zone.

Inadequate postflow time.

Loose or leaking gas fittings.

Water in torch.

Use proper size tungsten (see Section 7).

Use properly prepared tungsten (see Section 7).

Reduce shielding gas flow rate (see Section 3-7).

Shield weld zone from drafts.

Allow adequate postflow time to shield tungsten while it cools, after welding stops.

Check and tighten all gas fittings (see Section 3-7).

Refer to torch manual.

OM-220 812 Page 25

SECTION 6 − ELECTRICAL DIAGRAMS

OM-220 812 Page 26

Figure 6-1. Circuit Diagram

206 171-D

SECTION 7 − SELECTING AND PREPARING

TUNGSTEN ELECTRODE

gtaw 7/97

NOTE

For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent contamination of tungsten electrode.

7-1. Selecting Tungsten Electrode

Electrode Diameter DC − Argon − Electrode

2% Thorium Alloyed

Tungsten (Red Band)

.010” Up to 25 * Up to 20 Up to 15 .020” 15-40 * 15-35 5-20 .040” 25-85 * 20-80 20-60 1/16” 50-160 10-20 50-150 60-120 3/32” 135-235 15-30 130-250 100-180

1/8” 250-400 25-40 225-360 160-250 5/32” 400-500 40-55 300-450 200-320 3/16” 500-750 55-80 400-500 290-390

1/4” 750-1000 80-125 600-800 340-525

Negative/Straight Polarity

Amperage Range - Gas Type♦ - Polarity

DC − Argon − Electrode

Positive/Reverse Polarity

AC − Argon − Using

High Frequency

AC − Argon − Balanced

Wave Using High Freq.

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).

*Not Recommended.

The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

7-2. Safety Information About Tungsten

 Grinding the tungsten elec-

trode produces dust and flying sparks which can cause

injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

1 Tungsten Electrode With

Balled End

2 Pointed Tungsten Electrode

Ref. S-0161

OM-220 812 Page 27

7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding

1 Tungsten Electrode

Electrode Diameter

Ideal Tungsten Preparation − Stable Arc

2-1/2 Times

2 Tapered End Grind end of tungsten on fine grit,

hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

1 Stable Arc 2 Flat Diameter of this flat determines

amperage capacity. 3 Grinding Wheel Grinding wheel should be dedi-

cated to grinding tungsten only. 4 Straight Ground

Wrong Tungsten Preparation − Wandering Arc

1 Arc Wander 2 Point 3 Grinding Wheel Grinding wheel should be dedi-

cated to grinding tungsten only. 4 Radial Ground

Ref. S-0161 / Ref. S-0162

OM-220 812 Page 28

Notes

OM-220 812 Page 29

SECTION 8 − PARTS LIST

 Hardware is common and

not available unless listed.

OM-220 812 Page 30

803 157-B

Figure 8-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-1. Main Assembly

1 205758 PANEL,FRONT W/CMPNT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 205780 PANEL,REAR W/CMPNT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 212809 MAGNETICS SUBASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 206090 HEAT SINK ASSEMBLY,OUTPUT DIODE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 206039 BASE ASSY, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 206093 BRACKET,MTG CAPACITORS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 206038 HEAT SINK ASSEMBLY,INPUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 206164 COVER,TOP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 206165 PANEL,SIDE LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 206166 PANEL,SIDE RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 207437 CABLE,POWER 6 FT 10GA 4C BLK/RED/WHT/GRNYEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 206108 HANDLE,RUBBERIZED CARRYING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 206289 LINK,CONNECTING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 PLG3 206247 PLUGS,W/LEADS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 PLG4 206254 PLUGS,W/LEADS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 196231 XFMR,CURRENT SENSING 200/1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 206269 INSULATOR,SIDE LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 206270 INSULATOR,SIDE RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 PLG5 206276 CABLE,LEM W/PLUGS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 C1,C2 203912 CAPACITOR,ELCTLT 2400 UF 500 VDC CAN 2.5 DIA 2. . . . . . . . . . . . . . . . . . . . . . . . . .

21 205908 CLAMP,CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 189777 RAIL, HEAT SINK 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134327 LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE 1. . . . . . . . . . . . . . . . . . . . . . .

185835 LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182826 LABEL,WARNING ELECTRIC SHOCK POWER CORD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180994 LABEL,WARNING MATCH INPUT POWER TO VOLTAGE SHOWN 1. . . . . . . . . . . . . . . . . . . . . . . . .

23 PC2 222447 KIT,CIRCUIT CARD ASSY INTERCONNECT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 PC1 205772 CIRCUIT CARD ASSY,POWER CONTROL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 PC5 205776 CIRCUIT CARD ASSY,RELINK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 176879 SCREW,M 5− .8X 12 HEX HD−PHL 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 207113 WASHER,CONE .205IDX0.394ODX.015T STL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 186329 SCREW,M10−1.5X 25 HEX HD−PLN 8.8 PLD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-220 812 Page 31

 Hardware is common and

not available unless listed.

803 158

Figure 8-2. Panel, Front w/Components

Item No.

Diagram marking

Part No. Description

Figure 8-2. Panel, Front w/Components

1 194242 PANEL,FRONT/REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 205759 PANEL,FRONT UPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195647 PANEL,FRONT LOWER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S1 207165 SWITCH,W/LEADS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 174991 KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 174992 KNOB,POINTER .840 DIA X .250 ID W/SPRING CLIP−.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RC14 207144 RECEPTACLE W/LEADS&PLUG,(14 PIN) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 193115 STAND−OFF SUPPORT,PC CARD .156 DIA/.375 LG NYLON 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

9 178548 TERMINAL,CONNECTOR FRICTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 202553 RECEPTACLE,TWIST LOCK DINSE(FEMALE)POWER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 185712 INSULATOR,BULKHEAD FRONT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 185713 INSULATOR,BULKHEAD REAR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 185714 WASHER,TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN 2. . . . . . . . . . . . . . . . . . . . . . . . .

14 185717 NUT,M20−1.5 1.06HEX .19H BRS LOCKING 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 185718 O−RING, 0.989 ID X 0.070 H 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 186228 O−RING, 0.739 ID X 0.070 H 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 207253 BLANK,HEX HOLE BLACK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 220685 NAMEPLATE,MILLER CST 250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 PC4 205764 CIRCUIT CARD ASSY,OPERATOR INTERFACE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 PC3 220810 CIRCUIT CARD ASSY,PROCESS CONTROL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 170391 CONNECTOR, CIRC MS PROTECTIVE CAP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 178355 NUT, 375−32 .54HEX .25H NYL FLANGE .62D2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 209554 SCREW, KA35X 8 PAN HD−PHL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-220 812 Page 32

 Hardware is common and

not available unless listed.

803 161-B

Figure 8-3. Panel, Rear w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-3. Panel, Rear w/Components

1 194242 PANEL,FRONT/REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 206052 PANEL,REAR UPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 206053 PANEL,REAR LOWER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 210128 BRACKET,HEATSINK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 145217 SCREW,K40X 12 PAN HD−PHL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 207253 BLANK,HEX HOLE BLACK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 201155 BUSHING,STRAIN RELIEF .450/.709 ID X1.068 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-220 812 Page 33

 Hardware is common and

not available unless listed.

803 163-B

Figure 8-4. Magnetics Subassembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-4. Magnetics Subassembly

1 206063 PANEL,PLENUM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 T1 212812 XFMR,HF LITZ/LITZ W/BOOST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 FM 196887 FAN,MUFFIN 24VDC 3000 RPM 130 CFM 4.125 MTG HOLES 1. . . . . . . . . . . . . . . . . . . . .

4 Z1 206064 INDUCTOR,OUTPUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR1 206258 RELAY,ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG 1. . . . . . . . . . . . . . . . . . . . .

6 R3 206281 RESISTOR,W/LEADS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 C3 196143 CAPACITOR,POLYP MET FILM 16. UF 400 VAC 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 057357 BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 109056 CORE,FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 L3 206273 COIL,INDUCTOR (BOOST) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 196514 GASKET,INDUCTOR MOUNTING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 196512 BRACKET,INDUCTOR MOUNTING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 198634 BRACKET,FRONT HEATSINK MTG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 083147 GROMMET,SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 136343 SCREW,K50X 20 PAN HD−PHL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 170647 BUSHING,SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-220 812 Page 34

 Hardware is common and

not available unless listed.

803 159-C

Figure 8-5. Heat Sink Assembly, Output Diode

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-5. Heat Sink Assembly, Output Diode

1 205916 HEAT SINK,DIODE OUTPUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 D1,D2 223422 KIT,DIODE ULTRA−FAST RECOVERY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 SR1 201530 KIT,DIODE FAST RECOVERY BRIDGE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 HD1 191941 TRANSDUCER,CURRENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R2,C6 196510 RESISTOR/CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 R1,C5 207384 RESISTOR/CAPACITOR, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RT1 199798 THERMISTOR,NTC 30K OHM @ 25 DEG C 18IN LEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

8 049611 TUBING,COP .540 OD X .123 WALL X .687 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 207932 INSULATOR,HEATSINK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 108942 SCREW,250−20X1.25 HEXWHD.61D GR5 PLD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 602 062 SCREW,004−40X .37 PAN HD−PHL STL PLD CONE SEMS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 070427 SCREW,008−32X .50 SOC HD−HEX GR8 PLD 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 602200 WASHER,LOCK .168IDX0.293ODX.040T STL PLD SPLIT #8 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-220 812 Page 35

 Hardware is common and

not available unless listed.

Item

No.

Dia.

Mkgs.

Part

No.

Figure 8-6. Base Assembly

Description

Figure 8-6. Base Assembly

803 160

Quantity

1 206089 BASE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 019663 MOUNT,NPRN 15/16ODX3/8REC 3/16X3/8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C7,C8 186543 CAPACITOR ASSY, 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 133528 RIVET,AL .125 DIA X .188−.250 GRIP BLK BLIND DOME 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 195666 SCREW,010−32X .62 HEXWHD.40D STL PLD SLFFMG TAP−RW 2. . . . . . . . . . . . . . . . . . . . . . .

6 601862 NUT, 010−32 .38HEX .13H STL PLD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 602203 WASHER,LOCK .193IDX0.334ODX.047T STL PLD SPLIT #10 2. . . . . . . . . . . . . . . . . . . . . . . . . .

8 602238 WASHER,FLAT .203IDX0.500ODX.048T STL PLD ANSI#10 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-220 812 Page 36

 Hardware is common and

not available unless listed.

Ref. 803 162

Figure 8-7. Heat Sink Assembly, Input

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-7. Heat Sink Assembly, Input

1 205915 HEAT SINK,IGBT/INPUT RECTIFIER MODULE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 206091 BRACKET,HEATSINK REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TE1 206328 BLOCK,TERM 70 AMP 3 POLE SCREW TERM 4−14 WIRE 1. . . . . . . . . . . . . . . . . . . . . . .

OM-220 812 Page 37

Notes

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, 2005

(Equipment with a serial number preface of “LF” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

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 within 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 * Inverters (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 Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig * Maxstar 150 * 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 and Coolers * Water Coolant Systems (Non-Integrated) * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Maxstar 85, 140 * Spot Welders * Load Banks * Arc Stud Power Sources & Arc Stud Guns * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * 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

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets * APT & SAF Model Plasma Cutting Torches * Remote Controls * 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, 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.

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 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 1/05

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

Contact 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 Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

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.

Miller Electric CST 250 VRD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual