CST 250 - Miller Welding

OM-2237
206 035F
June 2003
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
CST 250
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
OM-2237
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Stick (SMAW) Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. TIG (GTAW) Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . .
2-8. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Selecting 230 Volts AC Single/Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Selecting 460/575 Volts AC Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Process Select Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Stick Start Procedure – Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Fan-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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 1-4. Read and follow all
Safety Standards.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Only qualified persons should install, operate, maintain, and
repair this unit.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Keep your head out of the fumes. Do not breathe the fumes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor 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 weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld 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 Z49.1
and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
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.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
OM-2237 Page 2
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2237 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2237 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-2237 Page 5
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-2237 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
Ne pas toucher des parties chaudes à mains nues
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
Rester à l’écart des organes mobiles comme le
ventilateur.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Ne pas installer l’appareil à proximité de produits inflammables
Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-2237 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-2237 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – INSTALLATION
2-1. Specifications
Welding
Mode
Input
Power
Rated
Output
Welding
Amperage
Range
Maximum
Amperes Input At Rated Load
Open-Circuit
Output, 50/60 Hz
Voltage
230
460
575
250 A @
30 VDC,
50 % Duty
Cycle
3-Phase
Stick
(SMAW)
200 A @
28 VDC,
100 %
Duty Cycle
5-250 A
150 A @
26 VDC,
100 %
Duty Cycle
5-200 A
KW
30.5
14.7
11.6
11.7
8.6
21.7
11.4
9.2
9.1
6.4
Dimensions
Net
Weight
H: 13-1/2 in
(343 mm)
W: 7-1/2 in
(191 mm)
D: 18 in (457
mm)
40 lb
(18.2 kg)
77 VDC
200 A @
28 VDC,
50 % Duty
Cycle
1-Phase
KVA
42.6
n/a
n/a
9.8
6.5
30.4
n/a
n/a
6.9
4.4
65 VDC
The primary input current draw is limited to 50 amperes; therefore, on 230 volts single phase, the unit may not make rating.
2-2. 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 duty cycle before
welding.
Exceeding duty cycle can
damage unit and void
warranty.
206 173
200 A @ 50% Duty Cycle For Single Phase Operation
5 Minutes Welding
250 A @ 50% Duty Cycle For 3 Phase Operation
5 Minutes Resting
5 Minutes Welding
5 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
OM-2237 Page 9
2-3. Stick (SMAW) Volt-Ampere Curves
xx10 Stick VA Curves
100
0
50
DC AMPS
150
100
200
250
300
350
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
shown.
90
80
DC VOLTS
70
60
50
40
30
20
10
0
100A SOFT
100A STIFF
150A SOFT
150A STIFF
200A SOFT
200A STIFF
250A SOFT
250A STIFF
xx18 Stick VA Curve
0
50
100
DC AMPS
150
200
250
300
350
100
90
80
DC VOLTS
70
60
50
40
30
20
10
0
100A SOFT
100A STIFF
150A SOFT
150A STIFF
200A SOFT
200A STIFF
250A SOFT
250A STIFF
Ref. 206174
OM-2237 Page 10
2-4. TIG (GTAW) Volt-Ampere 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.
TIG VA Curve
80
70
60
50
Volts
Min
10A
50A
100A
150A
200A
Max
40
30
20
10
0
0
50
100
150
Amps
200
250
300
Ref. 206174
OM-2237 Page 11
2-5. Selecting A Location
1
Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight
40 lb (18.2 kg) - with power cord
Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
18 in
(457 mm)
13-1/2 in
(343 mm)
7-1/2 in
(191 mm)
Location And Airflow
1
18 in
(460 mm)
18 in
(460 mm)
803 080
OM-2237 Page 12
2-6. Weld Output Terminals And Selecting Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
+ –
Output Receptacles
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Welding
Amperes***
10 – 60%
Duty
Cycle
60 – 100%
Duty
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)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
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)
10 – 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value.
S-0007-E–803 080
OM-2237 Page 13
2-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections
1
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
5
4
2
Negative (–) Weld Output
Terminal
6
Connect TIG torch to negative weld
output terminal.
3
3
4
Gas Cylinder
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5
6
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas
regulator/flowmeter.
1
7
hose
to
Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
2
7
Tools Needed:
11/16 in, 1-1/8 in, (21 mm)
Ref. 802 888 / Ref. 803 080
OM-2237 Page 14
2-8. Stick DCEP (Direct Current Electrode Positive) Connections
1
Negative (–) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2
Positive (+) Weld Output
Terminal
Connect electrode holder
positive weld output terminal.
to
2
1
Ref. 802 888 / Ref. 803 080
2-9. Electrical Service Guide
CAUTION:
INCORRECT INPUT POWER can damage this welding power source. This welding
power source requires a CONTINUOUS supply of 50/60 Hz power at +10% of rated input voltage. Do
not use a generator with automatic idle device (that idles engine when no load is sensed) to supply
input power to this welding power source.
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input 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
230
230
460
575
Input Amperes At Rated Output
43
29
15
12
Time-Delay 2
50
35
15
10
Normal Operating 3
60
45
20
15
8
10
14
14
143 (44)
147 (45)
233 (71)
364 (111)
10
10
14
14
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 2002 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
OM-2237 Page 15
2-10. Selecting 230 Volts AC Single/Three Phase Input Voltage
Turn Off welding power
source, and disconnect
input
power
before
proceeding.
3 Top Cover Securing
Screws — Left And
Right Side Panel
2 Top Cover Securing
Screws — Front And
Rear Panel
Check input voltage available at
site.
1
Voltage Selection View
Window
The input voltage that the power
source is linked for appears in the
Voltage Selection View Window.
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
1
To change relinking board position,
remove top cover and left side
panel.
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.
Remove 4 screws from left side
panel, and panel can easily be
removed from unit.
2
2
3
Relinking Board
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.
Be sure to tighten all four screws
securing relinking board in place.
3
4
Tools Needed:
5/16 in
803 079 / 803 077
OM-2237 Page 16
2-11. Selecting 460 - 575 Volts AC Three Phase Input Voltage
Turn Off welding power
source, and disconnect
input
power
before
proceeding.
3 Top Cover Securing
Screws — Left And
Right Side Panel
2 Top Cover Securing
Screws — Front And
Rear Panel
Check input voltage available at
site.
1
Voltage Selection View
Window
The input voltage that the power
source is linked for appears in the
Voltage Selection View Window.
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
1
To change relinking board position,
remove top cover and left side
panel.
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.
2
Remove 4 screws from left side
panel, and panel can easily be
removed from unit.
3
2
3
4
Relinking Board
Unused Terminal
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 relinking board.
Be sure to tighten all four screws. Three
5
screws securing relinking board in place.
4
3
Tools Needed:
5/16 in
803 079 / 803 078
OM-2237 Page 17
2-12. Connecting Input Power
Disconnect and lockout/tagout input power before
connecting input conductors from unit.
Have only qualified persons
make this installation.
See rating label on unit and check
input voltage available at site.
3
1
1
2
Input And Grounding
Conductors
Line Disconnect Device
See Section 2-9.
For three-phase
operation:
Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
2
2
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
For single-phase
operation:
L1
Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
L2
3
L1
L2
L3
Green Or
Green/Yellow
Green Or
Green/Yellow
4
5
6
Always connect grounding
conductor first
= GND/PE
1
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor
as shown.
3
1
4
Green or
Green/Yellow
6
5
1
input_2 3/96 - 803 080
OM-2237 Page 18
SECTION 3 – OPERATION
3-1. Controls
2
5
3
4
1
6
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1
Power Switch
Use switch to turn unit and indicator light
On/Off.
2 Output Indicator Light
When unit is first energized this indicator
light flashes several times and then
illuminates continuously. When unit is shut
down, the indicator light flashes several
times and the cooling fan will run briefly,
then both will turn off completely.
3 Process Control
See Section 3-2.
4 Amperage Control
See Section 3-5.
5 High Temperature Shutdown Light
When unit is first energized this indicator
light illuminates for approximately 1 second
to provide visual confirmation that the light
is functioning properly (see Section 2-2).
6 Remote 14 Receptacle
204 301 / 803 080
OM-2237 Page 19
3-2. Process Select Control
1
Process Select Control
Rotate knob to select desired
process.
1
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 3-4). Make connections
according to Section 2-7.
Stick E XX18 Soft - This setting
provides a lower dig/arc force
setting
for
smooth
weld
perfromance. A stable weld puddle
with little arc “snap” gives excellent
weld bead appearance with
minimal spatter. Make connections
according to Section 2-8.
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 2-8.
RECOMMENDED PROCESS
SELECTIONS VS ELECTRODE TYPE
OM-2237 Page 20
ELECTRODE
TYPE
SUGGESTED PROCESS
SETTING
EXXX1
EXXX2
EXX10
EXX10
EXXX3
EXX18
EXXX4
EXX18
EXXX5
EXX18
EXXX6
EXX18
EXXX7
EXX18
EXXX8
EXX18
STAINLESS
EXX18
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 2-8.
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 2-8.
3-3.
Stick Start Procedure – Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
Electrode
Workpiece
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.
1
2
3
Normal open-circuit voltage is not
present before electrode touches
workpiece; only a low sensing voltage
is present between electrode and
workpiece. This allows electrode to
touch workpiece without overheating,
sticking, or getting contaminated.
3-4. Lift-Arc Start Procedure
Lift-Arc Start
With Lift-Arc selected, start arc
as follows:
Lift-Arc Start Method
1
“Touch”
1–2
Seconds
2
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point.
Hold
electrode
to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
Do NOT Strike Like A Match!
OM-2237 Page 21
3-5. Amperage Control
1
1
AMP ADJUST (Amperage
Control)
Rotate knob clockwise to increase
amperage (5-250 amps).
3-6. 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.
A
B
K
Socket*
J
Socket Information
I
H
C L N
M
D
G
E F
A
15 volts dc (not functional).
B
Contact closure to A completes 15 volts dc
contactor control circuit (not functional).
C
Output to remote control; 0 to +10 volts dc.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
K
Chassis common.
15 VOLTS DC
REMOTE
OUTPUT
CONTROL
803 080
GND
*The remaining sockets are not used.
3-7. 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.
3-8. Rack Mounting
This unit is capable of being rack mounted [see rack Owner’s Manual, OM-2238 (208 107)].
OM-2237 Page 22
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING
4-1. Routine Maintenance
Disconnect power before maintaining.
Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Do not remove case when
blowing out inside of unit
(see Section 4-2) .
Blow out inside. During
heavy service clean
monthly.
4-2. 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
OM-2237 Page 23
4-3. Troubleshooting
1
2
Output LED (Blue)
High Temperature LED
(Yellow)
1
2
803 080
Trouble
No weld output; unit completely
inoperative.
Possible Causes
Remedy
Line disconnect switch open.
Place line disconnect switch in On position (see Section
2-12).
Blown line fuse(s).
Check and replace line fuse(s), if necessary, or reset
circuit breaker (see Section 2-12).
Improper input power connections.
Check for proper input power connections (see Section
2-12).
Line voltage too high or too low.
No weld output.
Blue LED flashes continuously, yellow
LED off.
Unit not linked correctly.
Unit needs to be reset.
Line voltage must be within ±10%.
Check line voltage and link unit accordingly.
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
Blue LED flashes 4 times repeatedly, external source across output studs.
yellow LED off.
Check and correct any external voltage sources.
No weld output.
Short circuit across output studs.
Blue LED flashes 5 times repeatedly,
yellow LED off.
Check and correct any short circuit conditions.
Single phase rating exceeded (output
Low weld output.
Blue LED flashes 2 times repeatedly, foldback due to excessive input current).
yellow LED off.
High output VA coupled with a low 230
voltage line (output foldback due to
excessive input current).
Reduce output to 200 amperes or less.
No weld output.
Remote trigger left on.
Blue LED flashes 3 times repeatedly,
yellow LED off.
Turn off remote trigger, wait approximately 5 seconds, and
restart operation.
No weld output.
Internal component failure.
Blue LED flashes 6 times repeatedly,
yellow LED off.
Contact nearest Factory Authorized Service Agent.
No weld output.
Blue LED off, yellow LED on.
Unit overheated.
Allow unit to cool.
No weld output.
Blue LED off, yellow LED flashes
continuously.
Thermistor failure.
Have Factory Authorized Service Agent check thermistor.
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
Check line voltage and weld settings.
Trouble
Erratic or improper weld output.
Wandering arc
Possible Causes
Remedy
Weld cable too small or defective.
Use proper size and type of weld cable (see Section 2-6).
Dirty or loose connections.
Clean and tighten all weld connections (see Section 2-6).
Improper size tungsten.
Use proper size tungsten (see Section 6).
Worn or defective tungsten.
Use properly prepared tungsten (see Section 6).
Shielding gas flow too high.
Reduce shielding gas flow rate (see Section 2-7).
Tungsten electrode oxidizing and not Shielding gas blown away from weld
zone.
remaining bright after conclusion of
weld.
Inadequate postflow time.
Shield weld zone from drafts.
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 2-7).
Water in torch.
Refer to torch manual.
OM-2237 Page 25
SECTION 5 – ELECTRICAL DIAGRAMS
Figure 5-1. Circuit Diagram
OM-2237 Page 26
206 171-C
SECTION 6 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
6-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC – Argon – Electrode
Negative/Straight Polarity
DC – Argon – Electrode
Positive/Reverse Polarity
AC – Argon – Using
High Frequency
AC – Argon – Balanced
Wave Using High Freq.
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
2% Thorium Alloyed
Tungsten (Red Band)
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.
6-2. Safety Information About Tungsten
1
2
Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-level radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1
2
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
Ref. S-0161
OM-2237 Page 27
6-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
1
2
Diameter of this flat determines
amperage capacity.
3
3
Stable Arc
Flat
Grinding Wheel
Grinding wheel should be dedicated to grinding tungsten only.
4
Straight Ground
1
1
2
3
Arc Wander
Point
Grinding Wheel
2
Grinding wheel should be dedicated to grinding tungsten only.
4
Ideal Tungsten Preparation – Stable Arc
4
Radial Ground
3
4
Wrong Tungsten Preparation – Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-2237 Page 28
Notes
OM-2237 Page 29
SECTION 7 – PARTS LIST
Hardware is common and
not available unless listed.
12
8
27
21
20
13
6
26
15
25
15
14
9
7
14
24
23
19
11
16
3
22
17
2
4
10
19
28
18
1
5
803 157-B
Figure 9-1. Main Assembly
OM-2237 Page 30
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
. . . 1 . . . . . . . . . . 205758
. . . 2 . . . . . . . . . . 205780
. . . 3 . . . . . . . . . . 206037
. . . 4 . . . . . . . . . . 206090
. . . 5 . . . . . . . . . . 206039
. . . 6 . . . . . . . . . . 206093
. . . 7 . . . . . . . . . . 206038
. . . 8 . . . . . . . . . . 206164
. . . 9 . . . . . . . . . . 206165
. . . 10 . . . . . . . . . . 206166
. . . 11 . . . . . . . . . . 207437
. . . 12 . . . . . . . . . . 206108
. . . 13 . . . . . . . . . . 206289
. . . 14 . . PLG3 . 206247
. . . 15 . . PLG4 . 206254
. . . 16 . . . . . . . . . . 196231
. . . 17 . . . . . . . . . . 206269
. . . 18 . . . . . . . . . . 206270
. . . 19 . . PLG5 . 206276
. . . 20 . . C1,C2 . 203912
. . . 21 . . . . . . . . . . 205908
. . . 22 . . . . . . . . . . 189777
. . . . . . . . . . . . . . . . 134327
. . . . . . . . . . . . . . . . 185835
. . . . . . . . . . . . . . . . 182826
. . . . . . . . . . . . . . . . 180994
. . . 23 . . . . . . . . . . 204429
. . . 24 . . . PC1 . . 205772
. . . 25 . . . PC5 . . 205776
. . . 26 . . . . . . . . . . 176879
. . . 27 . . . . . . . . . . . 207113
. . . 28 . . . . . . . . . . 186329
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL,FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK ASSEMBLY,OUTPUT DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,MTG CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK ASSEMBLY,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,POWER 10 FT 10GA 4C BLK/RED/WHT/GRNYEL . . . . . . . . . . . . . .
HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINK,CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR,CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE,LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR,ELCTLT 2400 UF 500 VDC CAN 2.5 DIA . . . . . . . . . . . . . . . . . .
CLAMP,CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON . . . . . . . . . . . . .
RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE . . . . .
LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK POWER CORD . . . . . . . . . . . . . . . . . .
LABEL,WARNING MATCH INPUT POWER TO VOLTAGE SHOWN . . . . . . .
CIRCUIT CARD ASSY,POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,POWER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,RELINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,M 5– .8X 12 HEX HD–PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,CONE .205IDX0.394ODX.015T STL . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,M10–1.5X 25 HEX HD–PLN 8.8 PLD . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
6
2
2
+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
Hardware is common and
8
not available unless listed.
19
20
1
4
7
2
18
14
23
9
13
12
4
22
6
15
5
3
7
17
11
21
16
10
803 158
Figure 9-2. Panel, Front w/Components
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
907 116
907052
Figure 9-2. Panel, Front w/Components
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
..............
..............
..............
. . . . S1 . . . . . .
..............
..............
. . RC14 . . . . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
. . . PC4 . . . . . .
. . . PC3 . . . . . .
..............
..............
..............
OM-2237 Page 32
194242
205759
195647
207165
174991
174992
207144
193115
178548
209473
202553
185712
185713
185714
185717
185718
186228
207253
204301
205764
208057
170391
178355
209554
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
PANEL,FRONT UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
PANEL,FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
SWITCH,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP–.21 . . . 1 . . . .
KNOB,POINTER .840 DIA X .250 ID W/SPRING CLIP–.21 . . . . 1 . . . .
RECEPTACLE W/LEADS&PLUG,(14 PIN) . . . . . . . . . . . . . . . . . . . 1 . . . .
STAND–OFF SUPPORT,PC CARD .156 DIA/.375 LG NYLON . 4 . . . .
TERMINAL,CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
RECEPTACLE,TWIST LOCK TWECO(FEMALE)POWER . . . . . 2
RECEPTACLE,TWIST LOCK(FEMALE)POWER . . . . . . . . . . . . . . . . . . . .
INSULATOR,BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
INSULATOR,BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
WASHER,TOOTH 22MMID X 31.5MMOD 1.310–1MMT INTERN 2 . . . .
NUT,M20–1.5 1.06HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . 2 . . . .
O–RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
O–RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
NAMEPLATE,MILLER CST 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
CIRCUIT CARD ASSY,OPERATOR INTERFACE . . . . . . . . . . . . . 1 . . . .
CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . . . . . . . . 1 . . . .
CONNECTOR, CIRC MS PROTECTIVE CAP . . . . . . . . . . . . . . . . 1 . . . .
NUT, 375–32 .54HEX .25H NYL FLANGE .62D . . . . . . . . . . . . . . 2 . . . .
SCREW, KA35X 8 PAN HD–PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
1
1
1
1
1
1
1
4
2
2
2
2
2
2
2
2
1
1
1
1
1
2
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.
Hardware is common and
2
not available unless listed.
6
7
5
7
1
3
4
803 161-B
Figure 9-3. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Panel, Rear w/Components
...
...
...
...
...
...
...
1
2
3
4
5
6
7
. . . . . . . . . . 194242
. . . . . . . . . . 206052
. . . . . . . . . . 206053
. . . . . . . . . . 210128
. . . . . . . . . . 145217
. . . . . . . . . . 207253
. . . . . . . . . . . 201155
..
..
..
..
..
..
..
PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,REAR UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,K40X 12 PAN HD–PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING,STRAIN RELIEF .450/.709 ID X1.068 MTG HOLE . . . . . . . . . . . . .
1
1
1
1
2
1
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
Hardware is common and
13
not available unless listed.
8
14
7
3
8
12
11
16
10
9
6
8
1
15
5
2
4
803 163-B
Figure 9-4. Magnetics Subassembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Magnetics Subassembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
..........
. . . . T1 . .
. . . FM . .
. . . . Z1 . .
. . . CR1 . .
. . . . R3 . .
. . . . C3 . .
..........
..........
. . . . L3 . .
..........
..........
..........
..........
..........
..........
206063
206065
196887
206064
206258
206281
196143
057357
109056
206273
196514
196512
198634
083147
136343
170647
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL,PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN,MUFFIN 24VDC 3000 RPM 130 CFM 4.125 MTG HOLES . . . . . . . . . . .
INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY,ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . .
RESISTOR,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR,POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . . .
BUSHING,SNAP–IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . .
CORE,FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . . . . .
COIL,INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET,INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROMMET,SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH . . . . . . . . . . . . .
SCREW,K50X 20 PAN HD–PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING,SNAP–IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
3
1
1
1
1
1
1
2
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
Hardware is common and
10
not available unless listed.
11
12
12
13
13
4
7
6
2
9
3
8
1
5
803 159-C
Figure 9-5. Heat Sink Assembly, Output Diode
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-5. Heat Sink Assembly, Output Diode
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
. . . . . . . . . . 205916
. . D1,D2 . 206987
. . . SR1 . . 199952
. . . HD1 . . 191941
. . R2,C6 . 196510
. . R1,C5 . 207384
. . . RT1 . . 209223
. . . . . . . . . . . 049611
. . . . . . . . . . 207932
. . . . . . . . . . 108942
. . . . . . . . . . 602 062
. . . . . . . . . . 070427
. . . . . . . . . . 602200
..
..
..
..
..
..
..
..
..
..
..
..
..
HEAT SINK,DIODE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE,ULTRA–FAST RECOVERY 120A 400V DUAL SOT–227 . . . . . . . . . .
DIODE,POWER MODULE 50 AMP 600 V 1PH FAST RECOVE . . . . . . . . . . .
TRANSDUCER,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR,NTC 30K OHM @ 25 DEG C 18IN LEAD . . . . . . . . . . . . . . . . .
TUBING,COP .540 OD X .123 WALL X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,250–20X1.25 HEXWHD.61D GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . .
SCREW,004–40X .37 PAN HD–PHL STL PLD CONE SEMS . . . . . . . . . . . . .
SCREW,008–32X .50 SOC HD–HEX GR8 PLD . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,LOCK .168IDX0.293ODX.040T STL PLD SPLIT #8 . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
5
7
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
Hardware is common and
not available unless listed.
3
1
6
7
8
4
2
5
803 160
Figure 9-6. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-6. Base Assembly
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
..........
..........
. . C7,C8 .
..........
..........
..........
..........
..........
206089
019663
186543
133528
195666
601862
602203
602238
..
..
..
..
..
..
..
..
BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNT,NPRN 15/16ODX3/8REC 3/16X3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RIVET,AL .125 DIA X .188–.250 GRIP BLK BLIND DOME . . . . . . . . . . . . . . .
SCREW,010–32X .62 HEXWHD.40D STL PLD SLFFMG TAP–RW . . . . . . . .
NUT, 010–32 .38HEX .13H STL PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,LOCK .193IDX0.334ODX.047T STL PLD SPLIT #10 . . . . . . . . . . .
WASHER,FLAT .203IDX0.500ODX.048T STL PLD ANSI#10 . . . . . . . . . . . . .
1
4
2
4
2
2
2
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 36
Hardware is common and
not available unless listed.
2
1
3
Ref. 803 162
Figure 9-7. Heat Sink Assembly, Input
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-7. Heat Sink Assembly, Input
. . . 1 . . . . . . . . . . 205915 . . HEAT SINK,IGBT/INPUT RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206091 . . BRACKET,HEATSINK REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . TE1 . . 206328 . . BLOCK,TERM 70 AMP 3 POLE SCREW TERM 4–14 WIRE . . . . . . . . . . . . . 1
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
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
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