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OM-2237 206 035H
July 2005
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
CST 250
Visit our website at
www.MillerWelds.com
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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 bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation,
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding Ha
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. 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 li
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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 Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- (phone: 305-443-9353, website: www.aws.org). ternational.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection, ting of Conta
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SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux Identifie un message de sécurité particulier. PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et
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LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation. tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien ventiler les espaces confinés ou porter un
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2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. Ne pas placer l’appareil sur une surface inflam- Se tenir à l’écart des organes mobiles comme les mable, ni au −dessus ou à proximité d’elle. ventilateurs. Maintenir fermés et bien fixés les portes, Ne pas installer l’appareil à proximité de produits inflammables. panneaux, recouvrements et dispositifs de
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2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463 −6727 ou à Toronto : (416) 747 −4044, site Web : www.csa−interna- (téléphone : (305) 443 −9353, site Web : www.aws.org). tional.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protect
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SECTION 3 − INSTALLATION 3-1. Specifications Welding Input Rated Welding Maximum Amperes Input At Rated Load Net Mode Power Output Amperage Open-Circuit Output, 50/60 Hz KV KVA A KW KW Dimensions Dimensions W We eight ight Range Range V Voltage oltage 230 460 575 250 A @ 30 VDC, 30.5 14.7 11.6 11.7 8.6 50 % Duty Cycle 3 3-Phase -Phase 5-250 A 5-250 A 77 77 VDC VDC 200 A @ 28 VDC, H: 13-1/2 in 21.7 11.4 9.2 9.1 6.4 100 % (343 mm) Duty Cycle Stick Stick W W: : 7 7-1/2 in 1/2 in 40 lb 40 lb (SMAW)
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3-3. Stick (SMAW) Volt-Ampere Curves Volt-ampere curves show minimum xx10 Stick VA Curves and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves DC AMPS shown. 0 50 100 150 200 250 300 350 100 90 80 70 60 50 40 30 20 10 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 90 80 70 60 50 40 30 20 10 0 100A SOFT 100A STIFF 150A STIFF 200A
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3-4. TIG (GTAW) Volt-Ampere Curve Volt-ampere curves show minimum TIG VA Curve and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves 80 shown. 70 60 50 Min 10A 50A 40 100A 150A 200A Max 30 20 10 0 0 50 100 150 200 250 300 Amps Ref. 206174 OM-2237 Page 11 Volts
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3-5. Selecting A Location 1 Line Disconnect Device Locate unit near correct input power supply. Dimensions And Weight Special installation may be required where gasoline or 40 lb (18.2 kg) - with power cord volatile liquids are present − see NEC Article 511 or CEC 18 in Section 20. (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
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3-6. Weld Output Terminals And Selecting Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) 10 − 60% 60 − 100% Weld Output Welding Duty Duty 10 − 100% Duty Cycle Terminals Amperes*** 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)
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3-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections 1 Positive (+) Weld Output Terminal Connect work lead to positive weld output terminal. 4 2 Negative ( −) Weld Output 5 Terminal 6 Connect TIG torch to negative weld output terminal. 3 Gas Cylinder 3 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/fl
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3-8. Stick DCEP (Direct Current Electrode Positive) Connections 1 Negative ( −) Weld Output Terminal Connect work lead to negative weld output terminal. 2 Positive (+) Weld Output Terminal Connect electrode holder to positive weld output terminal. 2 1 Ref. 802 888 / Ref. 803 080 3-9. Electrical Service Guide CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of 50/60 Hz power at 10% of rated input voltage. Do not use a g
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3-10. Selecting 230 Volts AC Single/Three Phase Input Voltage Turn Off welding power source, and disconnect input power before proceeding. 3 Top Cover Securing Check input voltage available at Screws — Left And site. Right Side Panel 1 Voltage Selection View 2 Top Cover Securing Window Screws — Front And The input voltage that the power Rear Panel source is linked for appears in the Voltage Selection View Window. Check voltage selected in unit. Changing selection is only necessary if selected
