Miller Electric CST 250 User's Manual
Contents
1. 17 3 12 Connecting MPU POWER vos x ucc n MIR A ice de ere SED ale aw ee o m d c 18 SECTION OPERATION xz ues od bx e mug Rue d eds Bene eee niet Oe Ed eq EO CUS EO OR UR d 19 Bele CONTO ner de due die tin nd an nana dis don 0 D Sion dl to noi ue 19 4 2 Process Select Control arci ecce ead douaniers CR od CX OR ion a dre 20 4 3 Stick Start Procedure Scratch Start Technique o 21 44 LIAE Start Procedure 2c cha seen dau cor tee Ce Roe ner nie rdc a d e es 21 45 Ampetage Conwell s eai otter doen sca nae Ro Oe or ane Rc ea DRE di ee earn 22 4 6 Remote 14 Receptacle Information l l 22 4 7 Fan OnsDemandg 22 23 acu as eoe au a ice Ra ee D I ola e DEL a I e Ree d 22 406 Hack MOLUDUDOS acies te cem E LUN Ad a eq Eta Steuer d rcs 22 SECTION 5 MAINTENANCE AND TROUBLESHOOTING o 23 S k COLE LORS AL LES Ta 7 LR 23 92 BIOWING QUE Asides OU Nitsa cnt nae Ana dann ipd 23 5 9 THOUDICSMOOLING A REA ER kaa a R N EN READ E at Sevens Sih A R tla et UR oh aA Sa 24 SECTION 6 ELECTRICAL DIAGRAMS saunas in severe dee A ue 26 SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE 27 7 1 Selecting Tungsten Electrode e eee nnn 27 7 2 Safety Information About Tungsten 0 cc nr 27 7 3 Preparing Tungsten For AC Or DC Electrode Negative DCEN Welding 28 SECTIONS PARTS EIST ice tara2. NOTE Green on nameplate indicates a TIG 2 Output Indicator Light 4 Amperage Control function Gray indicates a Stick function When unit is first energized this indicator See Section 4 5 1 Power Switch ius bodie baie e a 2 5 High Temperature Shutdown Light minates continuously When unit is shu a s Se Use switch to turn unit and indicator light un e ight flashes several 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 On Off times and the cooling fan will run briefly then both will turn off completely 3 Process Control See Section 4 2 204 301 803 080 OM 2237 Page 19 4 2 Process Select Control C PROCESS SELECT RECOMMENDED PROCESS SELECTIONS VS ELECTRODE TYPE ELECTRODE SUGGESTED PROCESS TYPE SETTING EXXX1 EXX10 EXXX2 EXX10 EXXX3 EXXX4 EXXX5 EXXX6 EXXX7 EXXX8 STAINLESS OM 2237 Page 20 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 di
3. OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards i SS MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL 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 amp Safety Code Section 25249 5 et seq A 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 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere wit
4. LA nenore 14 Socket Socket Information A 15 volts de not functional 15 VOLTS DC OUTPUT B Contact closure to A completes 15 volts dc CONTACTOR contactor control circuit not functional C Output to remote control 0 to 10 volts dc REMOTE D Remote control circuit common OUTPUT CONTROL E 0 to 10 volts dc input command signal from remote control K Chassis common 803 080 GND The remaining sockets are not used 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 2237 Page 22 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5 1 Routine Maintenance Replace Clean and tighten unreadable weld terminals y labels 3 Months Repair Or Replace Cracked Cables And Cords 6 Months A Do not remove case when blowing out inside of unit see Section 5 2 7 Blow out inside During heavy service clean ea monthly p amp 5 2 Blowing Out Inside Of Unit A 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 O
5. le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution respirateur a adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxygene et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou tante mal piss s e Ne pas souder de m taux munis d un rev tement tels que la t le e Ne pas s enrouler les c bles autour du corps d acier galvanis e plomb e ou cadmi e moins que le rev tement e Sila pi ce soud e doit tre mise la terre le faire directement avec un n ait t enlev dans la zone de soudage que l endroit soit bien venti cable distinct l et si n cessaire porter un respirateur adduction d air Les e Ne pas toucher l lectrode quand on est en contact avec la pi ce la rev tements et tous les m taux renfermant ces l ments peuvent d terre ou une lectrode d une autre machine gager des fum es toxiques lorsqu on les soude OM 2237 Page 5 LES
6. ces arr ter imm diatement l appareil Faire r guli rement contr ler et entretenir l installation Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre Veiller souder une distance de 100 metres de tout quipement lectronique sensible Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de
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 from your local distributor OM 2237 Page 33 ICS Hardware is common and not available unless listed 803 163 B Figure 8 4 Magnetics Subassembly Item Diagram Part No marking No Description Quantity Figure 8 4 Magnetics Subassembly err tee 2060069 s PANELPLENUM 12 3 5 2 2 5 dan id old imite 1 2 ll 206065 4 XFMR HF LITZEITZ W BOOST eiii pci En ace E ache ne ien 1 3 FM 196887 FAN MUFFIN 24VDC 3000 RPM 130 CFM 4 125 MTG HOLES 1 224 aie N 206064 s INDUCTOR OUTPUT 41 1 eme re nee t abt ROI n 1 5 CR1 206258 RELAY ENCL 24VDC SPST 30A 240VAC 4PIN FLANGE MTG 1 lt AS 2s 206281 2 RESISTOR WILEADS sais vale si ie nee dost dis 1 7 C3 196143 CAPACITOR POLYP MET FILM 16 UF 400 VAC 10 1 Ol Hanks oo 057357 BUSHING SNAP IN NYL 937 ID X 1 125 MTG HOLE 3 I PDT 109056 CORE FERRITE E 2 164 LG X 1 094 HIGH X 826 WIDE 1 xx dO cee E3 ae 206273 a GOIEINDUGCTOR BOOST tnt a ete um cou ih Sc ha tea atc me prat ie es 1 ix i aot odis 196514 GASKET INDUCTOR MOUNTING 1 x E 196512 BRACKET INDUCTOR MOUNTING 1 um o m
8. 3 0 2 ea 3 0 G 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 70 2x95 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 size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use Select weld cable size for pulsing application at peak amperage value S 0007 E 803 080 OM 2237 Page 13 3 7 TIG Lift Arc 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 2237 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 Outpu
9. 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 t l phone 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 t l phone 617 770 3000 site Web www nfpa org et 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 de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu Laccumula tion de preuves n a pas d montr que l exposition aux champs mag
10. cause injury and start fires Use lo cal exhaust forced ventila tion 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 lev el radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Tungsten Electrode With Balled End 2 Pointed Tungsten Electrode Ref S 0161 OM 2237 Page 27 7 3 Preparing Tungsten For AC Or DC Electrode Negative DCEN Welding 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality 2 1 2 Times Electrode Diameter 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 Ideal Tungsten Preparation Stable Arc 1 Arc Wander 2 Point cated to grinding tungsten only 4 Radial Ground Pl 3 Grinding Wheel Grinding wheel should be dedi Wrong Tungsten Preparation Wandering Arc Ref S 0161 Ref S 0162 OM 2237 Page 28 Notes OM 2237 Page 29 SECTION 8 PARTS LIST ICS Hardware is common and not available unless listed 803 157 B
11. certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteiles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution endommag es e Prot ger les bouteilles de gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N tiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes D tourner la t te 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 e Lire et suivre les instructions concer
12. ded a deae RC e eie rs 20 C1 C2 203912 CAPACITOR ELCTLT 2400 UF 500 VDC CAN 2 5 DIA 4 PERDER 205908 CLAMP CAPACITOR 2 500 DIA HORIZONTAL MTG NYLON e dd id 189777 s RAIL HEAT SINK iu oer dri ad pec baa i eic acia nr CX RR ys Poti ie at Magi des 134327 LABEL WARNING GENERAL PRECAUTIONARY STATIC amp WIRE FE tai ee 185835 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTS PauU EA E M 182826 LABEL WARNING ELECTRIC SHOCK POWER CORD Sade Aun iron 180994 LABEL WARNING MATCH INPUT POWER TO VOLTAGE SHOWN 23 PC2 222446 KI CIRCUIT CARD ASSY POWER INTERCONNECT 24 PC1 205772 CIRCUIT CARD ASSY POWER CONTROL 25 2 POD va 205770 CIRCUIT CABD ASSY RELUINK 325 uu ur Ert te ER RC EA e Na NU iii 176879 SCREW M 5 8X 12 HEX HD PHL Lo d rA dE 207113 WASHER CONE 205IDX0 3940DX 015T STL SCO rachel este asa 200550 SCREW M10 1 5X 20 HEX HD PLN 8 8 PLD SEMS 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 2237 Page 31 ICS Hardware is common and not available
13. sont utilis s tout au long du pr sent e 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 mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apres ne font que r sumer le o contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure gt installation l utilisation l entretien et les r parations ne doi vent tre confi s qu a des personnes qualifi es gt Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants e Ps LES D CHARGES LECTRIQUES e peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement
14. sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact Ne pas connecter plus d une lectrode ou plus d un c ble de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger Ne jamais toucher aux pi ces lectriques sous tension Porter des gants et des v tements de protection secs et exempts de trous S isoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l ou on risque de tomber Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige Si l utilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re
15. 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 e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2237 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e 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 e 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
16. voltage and weld settings voltage line output foldback due to excessive input Current No weld output Remote trigger left on Turn off remote trigger wait approximately 5 seconds and Blue LED flashes 3 times repeatedly restart operation yellow LED off No weld output Internal component failure Contact nearest Factory Authorized Service Agent Blue LED flashes 6 times repeatedly yellow LED off No weld output Unit overheated Allow unit to cool Blue LED off yellow LED on No weld output Thermistor failure Have Factory Authorized Service Agent check thermistor Blue LED off yellow LED flashes continuously Fan not operating Blocked fan blade Check and remove anything blocking fan blade movement Fan failure Have Factory Authorized Service Agent check fan motor OM 2237 Page 24 Trouble Possible Causes Remedy 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 Improper size tungsten Use proper size tungsten see Section 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 weld Shielding gas blown away from w
17. 39 ID X 0 070H D ou 2 uu M snot Eds tec 207253 BLANK HEX HOLE BLACK dise A se UO TT 204301 NAMEPLATE MILLER CST 250 T I lO POE 2 cs 205764 CIRCUIT CARD ASSY OPERATOR INTERFACE Testa 20520 POS ais 208057 CIRCUIT CARD ASSY PROCESS CONTROL Tuus d Sud A Pina 170391 CONNECTOR CIRC MS PROTECTIVE CAP Duces mos c 178355 NUT 375 32 54HEX 25H NYL FLANGE 62D 2 2 Tope 209554 SCREW KA35X 8 PAN HD PHL 2 Sees 2 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 2237 Page 32 ICS Hardware is common and not available unless listed 7 803 161 B Figure 8 3 Panel Rear w Components Item Part No No Description Quantity Figure 8 3 Panel Rear w Components TA AAA 194242 PANEL FRONT REAR 000 ccc cece IR hn 1 Nc Meet es 206052 PANEL REAR UPPER nan ex i e EX ire ie eb ee tle ROG GRE Gb a CIC 1 nM I REN 206053 PANEL REAR LOWER 00d e APER Cu felit Sc Mut re ep ce eh 1 TL DET 210128 BRACKET AIEATSINK 555 ans pentes ia s 1 HE CHERCHER 145217 SCREW K40X 12 PAN HD PHL seee nn 2 E TEN 207253 i BEANK JAHEX HOLE BLACK cuina cer o e er ee at e ec 1 Mr OE
18. 57 50 Duty mm Cycle 1 Phase 5 200 A 65 VDC 150A O 26 VDC 100 Duty Cycle 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 5 PHASE cooling fan runs Wait fifteen OPERATION minutes for unit to cool Reduce amperage or duty cycle before SINGLE PHASE welding OPERATION Exceeding duty cycle can damage unit and void warranty WELDING AMPERES 50 60 DUTY CYCLE 206 173 200 A 50 Duty Cycle For Single Phase Operation 250 A 50 Duty Cycle For 3 Phase Operation 5 Minutes Welding 5 Minutes Resting 5 Minutes Welding 5 Minutes Resting Overheating Us Minutes Reduce Duty Cycle OM 2237 Page 9 3 3 Stick SMAW Volt Ampere Curves xx10 Stick VA Curves Volt ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source Curves of DC AMPS other settings fall between curves i 0 50 100 150 200 250 300 350 shown 90 80 70 y 60 5 S Au Qo 50 ba a S 40 ie 30 20 Z 10 y 0 100A SOFT 100A STIFF 150A STIFF 200A STIFF 150A SOFT 200A SOFT 250A SOFT 250A STIFF xx18 Stick VA Curve DC AMPS 0 50 100 150 200 250 300 350 100 DC VOLTS 2 100A SOFT 100A STIFF 150A STIFF 200A STIF
19. 9 9 9 RC3 10 gt d w dL RC3 9 VN NNM CU dO 900000 929 1d T28 3AILVO3N AAILISOd Figure 6 1 Circuit Diagram 206 171 C OM 2237 Page 26 SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7 97 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 Amperage Range Gas Type Polarity Electrode Diameter DC Argon Electrode DC Argon Electrode AC Argon Using AC Argon Balanced Negative Straight Polarity Positive Reverse Polarity High Frequency Wave Using High Freq 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 N 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 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 fly ing sparks which can
20. E 198634 BRACKET FRONT HEATSINK MTG 1 O EEPE E 083147 GROMMET SCR NO 8 10 PANEL HOLE 312 SQ 500 HIGH 1 NO A 136943 SCREW K50X 20 PAN HD PHL 353152150013 fad eR e trt as t ec s 2 Os EN MEE 170647 BUSHING SNAP IN NYL 1 312 ID X 1 500 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 from your local distributor OM 2237 Page 34 ICS Hardware is common and not available unless listed 803 159 C Figure 8 5 Heat Sink Assembly Output Diode Item Diagram Part No marking No Description Quantity Figure 8 5 Heat Sink Assembly Output Diode lasse 205916 HEAT SINKDBIODE OUTPUT iu ep in Rea che ide se ue 1 2 D1 D2 223422 KI DIODE ULTRA FAST RECOVERY annann nrnna 2 3 it SA 2015390 s NIDBIODE FAST RECOVERY BRIDGE 5 5 o ye di 1 4 HD1 191941 TRANSDUCER CURRENT 0 ccc ccc a rus 1 Dai 2067 196510 y RESISTOR GAPACITOR 34e bacs iaa dieto alioa x Centers 1 6 H1 65 207984 BESISTOH CAPAGCITOR eiii bee cte nce ride rere traten ais 1 7 RT1 209223 THERMISTOR NTC 30K OHM 25 DEG C 18IN LEAD 1 Br abad deis 049611 TUBING COP 540 OD X 123 WALL X 687 1 VN rere tre tre 207932 0 INSULATOR HEATSINK caos Re Re Cea Ue CER i n Ces 1
21. F 250A STIFF 150A SOFT 200ASOFT 250A SOFT Ref 206174 OM 2237 Page 10 TIG GTAW Volt Ampere Curve TIG VA Curve Volt ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown Ref 206174 OM 2237 Page 11 3 5 Selecting A Location 1 Line Disconnect Device Locate unit near correct input power supply Dimensions And Weight Special installation may be volatile liquids are present see NEC Article 511 or CEC 40 Ib 18 2 kg with power cord required where gasoline or Section 20 13 1 2 in 343 mm Location And Airflow 803 080 OM 2237 Page 12 3 6 Weld Output Terminals And Selecting Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200ft 250ft 300ft 350ft 400 n 100 ft 30 m Or Less 45 m 60m 70m 90m 105 m 120 m 10 60 60 100 Weld Output Welding E Terminals Amperes Duty Duty 10 100 Duty Cycle Cycle Cycle 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 E K 2 ea 2 0 2ea
22. Figure 8 1 Main Assembly OM 2237 Page 30 Item Part No No Description Quantity Figure 8 1 Main Assembly o or 205758 PANEL FRONT W CMPNT o B Tee 205780 PANEL REAR W GMPNT 5g ae dik god rta ta OR ca an Pe x le mca ate ec DN eee 206037 MAGNETICS SUBASSEMBLY o c 206090 HEAT SINK ASSEMBLY OUTPUT DIODE NE TT 206039924 BASE ASSY iria dit o datation wb aee ata Dr De Y 206093 BRACKET MTG CAPACITORS e 206038 HEAT SINK ASSEMBLY INPUT onc dened ews o a ta aient e es AN 206104 2 COVER TOP ta di id Li ere eee 206165 2 PANEL SIDE LR te road oa eee I pattonntaeiu 206166 z PANEL SIDE RA IT Bo eee ee 207437 CABLE POWER 6 FT 10GA 4C BLK RED WHT GRNYEL S EE 206108 HANDLE RUBBERIZED CARRYING bs e te boa teas 206289 S LINK CONNECTING 355 33 2 2 9 1 ety cede bie de C ee rcs 45 PEGS 206247 lt PLUGS WILEADS uu aditu ede ap te co curse a e e el Dec mri eee es 1945 PEGA 206254 44IPLUGS WLEADS sd dvd ai Pd Re Um dc V e Epic died rincer AO lec ioc is 196231 XFMR CURRENT SENSING 200 1 ja er m 206269 INSULATOR SIDE LH st ER Re Kor SURE Ev e e Re Re tn da cO ep EAS 206270 x INSULATOR SIDE RP 483 d RAN SR Bap ect echo esee ce e a tic tolto e ei i puede 195 5 PEGS 206276 GABEE LEM Wi PLUGS cuisine minis
23. IN 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 complet
24. M 2237 Page 23 5 3 Troubleshooting Output LED Blue High Temperature LED Yellow 803 080 Trouble Possible Causes Remedy No weld output unit completely Line disconnect switch open Place line disconnect switch in On position see Section inoperative 3 12 Blown line fuse s Check and replace line fuse s if necessary or reset circuit breaker See Section 3 12 Improper input power connections Check for proper input power connections See Section 3 12 No weld output Line voltage too high or too low Line voltage must be within 10 Blue LED flashes continuously yellow LED off 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 corrected contact nearest Factory Authorized Service Agent No weld output Voltage in excess of 100 V from an Check and correct any external voltage sources Blue LED flashes 4 times repeatedly external source across output studs yellow LED off No weld output Short circuit across output studs Check and correct any short circuit conditions Blue LED flashes 5 times repeatedly yellow LED off Low weld output Single phase rating exceeded output Reduce output to 200 amperes or less Blue LED flashes 2 times repeatedly foldback due to excessive input current yellow LED off High output VA coupled with a low 230 Check line
25. OM 2237 206 035H July 2005 Miller Stick SMAW Welding TIG GTAW Welding Description El 22 2 Arc Welding Power Source CST 250 IS OWNER S MANUAL 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 Ir Y E BL El Her 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 SUMING t Nert es you ce f f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick hassle free warranty In the i business and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for some reason t
26. RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage e Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 e Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit A H LE SOUDAGE peut causer un incen 3 die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de larc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas
27. SATION 5 2 1 Signification des symboles s pan trs n de eo Sot dice em oder RC ona oen os Do at ae C api 5 2 2 Dangers relatifs au soudage l arc anaran n renne 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes d S curit ass den dads acte donde olan CRE Gan ews a es 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 INSTALLATION 2 5 cic ec exu R a RET EA RISE IER LRE ER ETE 9 Sed HOPSCINCANONG ctas Gat Cerca oneness Beek Cu be aah LRL tai EE dur 9 3 22 Duty Cycle And Overhealllg seca e RI Ot AA eus 9 3 3 Stick SMAW Volt Ampere Curves lt arannana nnana 10 3 4 TIG GTAW VolbAmipere Curve gt i e Ex xe Sede tice ee deae wea e NR Rd 11 3 5 OLANTA LOCANON eos dro rr e tva rais vetro Ria een NS ae ee eer eer ees Chae 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 Te cani ex an ERE Ue RA Ne RES AE Ne ee Menu ee ee ne 15 3 10 Selecting 230 Volts AC Single Three Phase Input Voltage 16 3 11 Selecting 460 575 Volts AC Three Phase Input Voltage
28. a mE 108942 SCREW 250 20X1 25 HEXWHD 61D GR5 PLD 1 e 602 062 SCREW 004 40X 37 PAN HD PHL STL PLD CONE SEMS 5 EX AAA 070427 SCREW 008 32X 50 SOC HD HEX GR8PLD 7 o rr 602200 WASHER LOCK 168IDX0 2930DX 040T STL PLD SPLIT 28 7 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 2237 Page 35 ICS Hardware is common and not available unless listed 803 160 Figure 8 6 Base Assembly Item Diagram Part No marking No Description Quantity Figure 8 6 Base Assembly E AT RE eee 20009 TE BASE eura a EN 1 TER one oe ees 019663 MOUNT NPRN 15 160DX3 8REC 3 16X3 8 4 Laia ae OOO 186543 CAPACITOR IAS Yo taa iac NS oe eae A e Dutch e e abs se o 2 E Sree ener 133528 RIVET AL 125 DIA X 188 250 GRIP BLK BLIND DOME 4 TL m 195666 SCREW 010 32X 62 HEXWHD 40D STL PLD SLFFMG TAP RW 2 RS T 601862 NUT 010 32 38HEX 13H STL PLD og etiam ad eine et t ees 2 Ld de 602203 WASHER LOCK 1931DX0 3340DX 047T STL PLD SPLIT 10 2 JD ad s a aoe 602238 WASHER FLAT 203IDX0 5000DX 048T STL PLD ANSI 10 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model an
29. acelet antistatique AVANT de mani puler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage PAL LES ORGANES MOBILES peuvent causer des blessures e Setenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation Si la Federal Communications Commission signale des interf ren
30. 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 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 opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som fre 8 03 2 1 i A identifie un message de s curit particulier Signification des symboles Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance Il y a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de connaitre les me 7 Signifie NOTA n est pas relatif la s curit sures prendre pour viter tout danger 2 2 Dangers relatifs au soudage a l arc A Les symboles ci apr s
31. 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 oylinder 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 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e 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 e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit
32. d serial number required when ordering parts from your local distributor OM 2237 Page 36 ICS Hardware is common and not available unless listed Item Diagram Part No marking No Sen 205915 M MCA 206091 3 TE1 206328 Figure 8 7 Heat Sink Assembly Input Figure 8 7 Heat Sink Assembly Input HEAT SINK IGBT INPUT RECTIFIER MODULE BRACKET HEATSINK REAR BLOCK TERM 70 AMP 3 POLE SCREW TERM 4 14 WIRE Ref 803 162 Quantity 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 2237 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 guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin wa
33. de danger e Se prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud e Ne pas souder un endroit ou des tincelles peuvent tomber sur des substances inflammables e Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit e Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t e Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais
34. des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal m 7 lation la r paration ou l entretien de l appareil Couper tiqueter e Sila ventilation est insuffisante utiliser un respirateur adduction l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor d air agr mes de s curit l m l le s cest t T i ie a e Lire les fiches techniques de sant s curit FTSS et les instruc ee aie aaa ESE EE sere E tions du fabricant concernant les m taux les consommables les municipaux rev tements les nettoyants et les degraisseurs e Toujours v rifier la terre du cordon d alimentation V rifier et s assu e Netravailler dans un espace clos que s il est bien ventil ou porter un rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud
35. des pantalons sans revers des chaussures montantes et un masque e Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu gt a vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 2237 Page 6 LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de 79 non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr LES PIECES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e lls doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de
36. e 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 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 PRINTED IN USA 2005 Miller Electric Mfg Co 1 05 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 amp 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 GQ Miller
37. e to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard OM 2237 Page 15 3 10 Selecting 230 Volts AC Single Three Phase Input Voltage 2 A Turn Off welding power E source and disconnect input power before proceeding 3 Top Cover Securing Screws Left And Right Side Panel Check input voltage available at site 1 Volt lection Vi 2 Top Cover Securing reacia SUM SIR Screws Front And Rear Panel 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 D NZ nana aa To remove top cover remove 3 screws from both sides also remove 2 screws from front and rear panels Do Not Remove Handle Slightly separate front and rear panels away from top cover Lift up one end of top cover then lift up other end and remove top cover N NM Remove 4 screws from left side panel and panel can easily be removed from unit 2 Relinking Board 3 Terminal Screws Loosen terminal screws 4 Relinking Board Connection For 230 VAC Single Three Phase Input Power Slide relinking board off connected terminals move relinking board to correct input voltage terminals and secure relinking board C7 Be su
38. ee insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e 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 e 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 e Properly install and ground this equipment according to its Owners Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e 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 som 8 03 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instruc
39. egend 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 Equipmentthat 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 HERE
40. eld zone Shield weld zone from drafts Inadequate postflow time Allow adequate postflow time to shield tungsten while it cools after welding stops Loose or leaking gas fittings Check and tighten all gas fittings see Section 3 7 Water in torch Refer to torch manual OM 2237 Page 25 SECTION 6 ELECTRICAL DIAGRAMS 4 amp WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit GLG 09 0 2 Ng O4LNO9 1NJAANI NId Yt 24 EE naiai aag n CONDUCTOR D RIBBON CABLE C m O 20 m Ea Y Uds a 27 QM O QQ o 2 2 zm EZ GS As Z Q O O O an 4 G E amp da 4 x go n G 8 f P E En P i z z z m m m o D S S Fi y Z2 9 U c E m oo e m we RC13 ma O 5o v RC lt TOP m O Cj Rre BOT gt 3 jM m x FED E LE Se lt RC2 1 C o RC3 4 gt X RCl1 4 88 uz az RC3 3 gt lt RCII 6 SO x ee RC3 1 gt gt lt RC11 1 SG U Z B E 13 15 RETURN NR 70 2 RC3 2 gt lt RC11 3 RCS C1 2 ri RER gt lt RELI 2 Z rte Ce 88888 UA a 3333 QA 0t 2 GATE 1 LO SR BREG A RC4 2 gt Donne Q 17 GATE 2 HI d uw RC4 8 gt N A RC4 7 gt 3i 7 RC4 3 99 2 15 SUPPLY X RC1 3 o a E Q e s RR SUPPLY 2 15 SUPPLY X scis S E RC4 1 gt gt COMMON lt RC1 1 z gt eae ar NOT READY o NOT READY Y 9
41. g arc force setting Tor 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 4 3 Stick Start Procedure Scratch Start Technique 4 4 Lift Arc Start Procedure Touch Seconds Do NOT Strike Like A Match 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 Lift Arc Start With Lift Arc selected start arc as follows 1 TIG Elect
42. h 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 2237 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 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 Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion 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 web site 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 electro magnet
43. h radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f 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 WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf 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 birt
44. he unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in EGN oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided 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 C Miller Mil_ Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad SYMDOl USAGE 2 ES et cca o Me ets eee een Rudi nbn ae tae ees 1 162 Arc Welding Hazards a oh a ie eae Ae a neue aie deu a Les ur Esa 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 15s P ncipal Satety Standarda e caris dd po dete ened ke idee Qu dic rnt a eee ate 4 156 EMF IBTOTETIS OTI s aac ado ns node as i TTT 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILI
45. ic 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 committees judgment has not demonstrated that exposure to power frequency 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 OM 2237 Page 4 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 Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q
46. linking board C7 Be sure to tighten all four screws Three screws securing relinking board in place Tools Needed A 8 5 16 in 803 079 803 078 OM 2237 Page 17 3 12 Connecting Input Power Disconnect and lockout tag out input power before connecting input conduc tors from unit Have only qualified persons make this installation See rating label on unit and check input voltage available at site 1 Input And Grounding 3 NG 1 ENG Conductors 2 Line Disconnect Device d SERBIA y IPS Vp S See Section 3 9 gy 3 f S f For three phase operation Always connect green or green yellow wire to supply grounding terminal never to a line terminal ES AENEAN 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 ISLISIS ISL ISI Green Or Green Or Green Yellow Green Yellow A Always connect grounding 6 Electrical Tape conductor first GND PE Insulate and isolate red conductor as shown pP d Green or Green Yellow f N input_2 3 96 803 080 OM 2237 Page 18 SECTION 4 OPERATION 4 1 Controls 5 250 POWER AMP ADJUST Miller CST 250 MILLER ELECTRIC MFG CO APPLETON WI
47. n tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiquespendant le soudage ou le coupage OM 2237 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 INSTALLATION 3 1 Specifications Welding Input Rated Welding Maximum Amperes Input At Rated Load Mode Power Output Amperage Open Circuit Output 50 60 Hz Range Voltage 230 460 575 250 A O 30 VDC 50 Duty 14 7 11 6 Cycle 3 Phase 5 250 A 77 VDC 200 e 4 H 18 1 2 in 343 mm Duty Cycle W 7 1 2 in Stick SMAW 200 A O 191 mm 28 VDC D 18 in 4
48. nant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit 2 3 Autres symboles relatifs l installation au fonctionnement et a l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle e Ne pasinstaller l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Nutiliser que l anneau de levage pour lever lap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s E lt lt i e Mettre un br
49. re to tighten all four screws securing relinking board in place Tools Needed A 8 5 16 in 803 079 803 077 OM 2237 Page 16 3 11 Selecting 460 575 Volts AC Three Phase Input Voltage 2 A Turn Off welding power wow source and disconnect input power before proceeding 3 Top Cover Securing Check input voltage available at Screws Left And site Right Side Panel l 1 Voltage Selection View 2 Top Cover Securing Window 25 Screws Front And l A S Rear Panel 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 D NZ nana aa To remove top cover remove 3 screws from both sides also remove 2 screws from front and rear panels Do Not Remove Handle Slightly separate front and rear panels away from top cover Lift up one end of top cover then lift up other end and remove top cover N NM Remove 4 screws from left side panel and panel can easily be removed from unit 2 Relinking Board 3 Unused Terminal 4 Terminal Screws Loosen terminal screws 5 Relinking Board Connection For 460 575 VAC Input Power Slide relinking board off connected terminals move relinking board to correct input voltage terminals and secure re
50. rode 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 OM 2237 Page 21 4 5 Amperage Control 1 AMP ADJUST Amperage Control Rotate knob clockwise to increase 1 125 150 100 175 amperage 5 250 amps 15 200 50 225 25 5 250 AMP ADJUST 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
51. rrants 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 Max
52. s consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e 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 e 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 2237 Page 1 ARC RAYS can burn eyes and skin 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 249 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 lea
53. s os ns AER a 30 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage i Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols CS 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 E s 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 power circuit and machine internal circuits are also 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 e Do nottouch live electrical parts e Wear dry hole fr
54. star 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire 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 HE Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp 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 m Miller 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers 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 L
55. stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 2237 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI 249 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 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 t l phone 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 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org
56. t Terminal Connect electrode holder to positive weld output terminal Ref 802 888 Ref 803 080 3 9 Electrical Service Guide A 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 Actual input voltage cannot exceed 10 of indicated required input voltage If actual input voltage is outside of this range no output is available 50 60 Hz Single Phase 50 60 Hz Three Phase 50 Duty Cycle 50 Duty Cycle Input Voltage 230 230 460 575 Input Amperes At Rated Output 43 31 15 12 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 50 35 15 10 Normal Operating 3 60 45 20 15 Min Input Conductor Size In AWG Kcmil 8 10 14 14 Max Recommended Input Conductor Length In Feet Meters 143 44 147 45 233 71 364 111 Min Grounding Conductor Size In AWG Kcmil 10 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 Failur
57. ther and wool and foot protection T 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 workpiece and hot equipment can cause fires and 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 e Watch for fire and keep a fire extinguisher nearby OA 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
58. tions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e 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 e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e 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 e 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 manufacturers instructions for metal
59. unless listed 16 10 803 158 Figure 8 2 Panel Front w Components Quantity Item Diagram Part Model No marking No Description 907 116 907052 Figure 8 2 Panel Front wComponents x I 194242 PANEL FRONT REAR nanan Ti nue P ee ea O 205759 PANEL FRONT UPPER ede dun a asus dise de Steer A UR ee eee 195647 PANEL FRONT LOWER T ecu d pid A eee 207165 lt SWITCH W LEADS isr tud en e deles edd De ote C etos T exe 1 NE ONERE NUT 174991 KNOB POINTER 1 250 DIA X 250 ID W SPRING CLIP 21 1 1 TEE tot 174992 KNOB POINTER 840 DIA X 250 ID W SPRING CLIP 21 1 1 7 RC14 usus 207144 RECEPTACLE W LEADS amp PLUG 14 PIN Tessi d E eee P 193115 STAND OFF SUPPORT PC CARD 156 DIA 375 LG NYLON 4 4 TE TEPE seo db td 178548 TERMINAL CONNECTOR FRICTION ii e A 209473 RECEPTACLE TWIST LOCK TWECO FEMALE POWER 2 PU A 202553 RECEPTACLE TWIST LOCK DINSE FEMALE POWER 2 Lo Tartes etr 185712 INSULATOR BULKHEAD FRONT 2 cox 2 qu A a ee eer ee 185713 INSULATOR BULKHEAD REAR 2 ss 2 OS A 185714 WASHER TOOTH 22MMID X 31 5MMOD 1 310 1MMT INTERN 2 2 zt esaet aac 185717 NUT M20 1 5 1 06HEX 19H BRS LOCKING 2 ck E M M E 185718 O RING 0 989 ID X 0 070 H Presse To HE 186228 O RING 0 7
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