Miller Electric CST 250 VRD International Owner'S Manual Download Page 1

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Processes

Description

Stick (SMAW) Welding

OM-220 812B

March 2005

Arc Welding Power Source

TIG (GTAW) Welding

CST 250 VRD

International

Summary of Contents for CST 250 VRD International

Page 1: ...Visit our website at www MillerWelds com Processes Description Stick SMAW Welding OM 220 812B March 2005 Arc Welding Power Source TIG GTAW Welding CST 250 VRD International ...

Page 2: ...nue 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 q...

Page 3: ...lecting 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 Se...

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Page 5: ...t 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 d...

Page 6: ...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 FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sl...

Page 7: ... qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat 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 ARC ...

Page 8: ...hone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent 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...

Page 9: ... 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 ...

Page 10: ...uile 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 LES PARTICULES PROJETÉES peu vent blesser les yeux Le soudage le burinage le passage de la pièce à la brosse métallique et le meulage provoquent l émission d étincelles...

Page 11: ...positifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de causer des interférences Le rayonnement haute fréquence peut causer des interférences avec les équipements de radio navigation 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...

Page 12: ...s for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 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 ef...

Page 13: ...Duty Cycle 5 200 A 30 VDC 42 6 n a n a 10 0 6 6 W 7 1 2 in 191 mm D 18 in 457 mm 40 lb 18 2 kg 1 Phase 150 A 26 VDC 100 Duty Cycle 5 200 A 30 VDC 33 6 n a n a 7 4 5 7 3 2 Duty Cycle And Overheating 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 d...

Page 14: ...ding power source Curves of other settings fall between curves shown DC VOLTS DC AMPS XX10 STICK VA 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 SOFT 250A STIFF XX18 STICK VA CURVES DC AMPS DC VOLTS 0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 90 30A SOFT 30A STIFF 250A SOFT 250A STIFF ...

Page 15: ...Curve Volt amperecurves show minimum and maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown LIFT ARC TIG GTAW DC AMPS DC VOLTS 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 ...

Page 16: ...input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 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 in 191 mm Dimensions And Weight 40 lb 18 2 kg with power cord ...

Page 17: ... 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 2 ea 2 0 2x70 2 ea 2 0 2x70 Output Receptacles 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 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...

Page 18: ...ct 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 2 Tools Needed 1...

Page 19: ...voltage is outside of this range no output is available NOTE 50 60 Hz Single Phase 50 Duty Cycle 50 60 Hz Three Phase 50 Duty Cycle Input Voltage 220 220 400 440 Input Amperes At Rated Output 45 32 18 16 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 50 40 20 20 Normal Operating 3 70 50 25 25 Min Input Conductor Size In AWG Kcmil 8 10 14 14 Max Recommended Input Conductor Length In...

Page 20: ...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 ...

Page 21: ...cted 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 vol...

Page 22: ...upply 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 L1 2 2 1 1 3 1 6 5 4 L2 L3...

Page 23: ...times and then illuminatescontinuously 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 confi...

Page 24: ...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...

Page 25: ...ocedure 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 b...

Page 26: ...sed on the AMP ADJUST control setting A J B K I Socket Socket Information B K I C L N H D M G 15 VOLTS DC A 15 volts dc not functional D M G E F 15 VOLTS DC B Contact closure to A completes 15 volts dc contactor control circuit not functional C Output to remote control 0 to 10 volts dc REMOTE OUTPUT CONTROL D Remote control circuit common CONTROL E 0 to 10 volts dc input command signal from remote...

Page 27: ...s Clean and tighten weld terminals Replace Damaged Gas Hose 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Blow out inside During heavy service clean monthly Do not remove case when blowing out inside of unit see Section 5 2 5 2 Blowing Out Inside Of Unit 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...

Page 28: ...ect any external voltage sources No weld output Blue LED flashes 5 times repeatedly yellow LED off Short circuit across output studs Check and correct any short circuit conditions Low weld output Blue LED flashes 2 times repeatedly yellow LED off Single phase rating exceeded output foldback due to excessive input current Reduce output to 200 amperes or less yellow LED off High output VA coupled wi...

Page 29: ...n 7 Worn or defective tungsten Use properly prepared tungsten see Section 7 Shielding gas flow too high Reduce shielding gas flow rate see Section 3 7 Tungsten electrode oxidizing and not remaining bright after conclusion of Shielding gas blown away from weld zone Shield weld zone from drafts g g weld Inadequatepostflow time Allow adequate postflow time to shield tungsten while it cools after weld...

Page 30: ...OM 220 812 Page 26 SECTION 6 ELECTRICAL DIAGRAMS Figure 6 1 Circuit Diagram 206 171 D ...

Page 31: ... 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 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 Ref S 0161 Grinding the tungsten elec trode pr...

Page 32: ...n become contami nated causing lower weld quality 3 Ideal Tungsten Preparation Stable Arc 2 1 2 Times Electrode Diameter 1 2 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 3 1 2 1 Arc Wander 2 Point 3 Grinding Wheel Grinding wheel should be dedi cated to grinding tungsten only 4...

Page 33: ...OM 220 812 Page 29 Notes ...

Page 34: ...20 812 Page 30 SECTION 8 PARTS 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: ...APACITOR 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 INTERCONNEC...

Page 36: ...NECTOR 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 1...

Page 37: ...NEL 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 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts fro...

Page 38: ... 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 S...

Page 39: ...2 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 ...

Page 40: ...SSY 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 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts M...

Page 41: ... Heat Sink Assembly Input Quantity 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 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 ...

Page 42: ...Notes ...

Page 43: ...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 Trail...

Page 44: ... retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you 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 Contact the Delivering ...

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