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Summary of Contents for Miller CST 250/Maxstar 200 Dual Rack Kit
- Page 1 OM-213 592A April 2003 Processes Stick (SMAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description CST 250/Maxstar 200 Dual Rack Kit Visit our website at www.MillerWelds.com...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
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. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. -
Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation
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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité... -
Page 12: Principales Normes De Sécurité
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 - Installation
SECTION 2 – INSTALLATION 2-1. Specifications For Dual Racks Used With CST 250 Models Input Power Input Power Capacity Capacity To Rack To Rack 460 Or 575 Volts AC; 50/60 Hz; Three Phase 1 – 8 Welding Power Sources 2-2. Specifications For Dual Racks Used With Maxstar 200 Series Models Input Power Input Power Capacity... -
Page 14: Control Box Setup
2-4. Control Box Setup Have only qualified persons make this installation. Y Turn Off and disconnect input power. Control Box Snap-In Blank Remove snap-in blank from control box. If control box does not have the hole with snap-in blank, a hole must be made according to the hole location drawing. -
Page 15: Installing Brackets
2-5. Installing Brackets Y Disconnect input power to racks. Assembly all clamps, plates and brackets, to racks before tightening hardware. Upper Clamp, Plate And Hardware (2 Pair) Install front and rear clamp and plate using 1/2–13 x 3 in screws and lock nuts. -
Page 16: Front And Rear Upper Clamp And Plate Location
2-6. Front And Rear Upper Clamp And Plate Location Y Disconnect input power to racks. Front Upper Clamp And Plate Rear Upper Clamp And Plate Position front and rear upper clamp and plate as shown. Tighten all hardware according to the Hardware Torque Chart. -
Page 17: Electrical Connections Between Control Boxes
2-7. Electrical Connections Between Control Boxes Service Loop Tools Needed: 803 533-A Y Disconnect input power to racks. Install power cable through strain reliefs Ground Terminal between control boxes. Be sure to allow a Control Boxes Connect grounding conductor to ground service loop in cable between boxes. -
Page 18: Connecting Input Power To Dual Racks
2-8. Connecting Input Power To Dual Racks Have only qualified persons make this installation. Y Turn Off welding power sources before inspecting or installing dual racks. Control Box Tools Needed: Open access door. Line Disconnect Device Of Proper Rating Input Conductors Grounding Conductor Select size and length using Section 2-9 or 2-10. -
Page 19: Electrical Service Guide For Cst 250 Dual Racks
2-9. Electrical Service Guide For CST 250 Dual Racks 50/60 Hz Three Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Operating 3 Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) (92) (120) Min Grounding Conductor Size In AWG... - Page 20 2-11. Installing Optional Running Gear (195 114) Onto Dual Racks Item Part Description (Qty) 209 396 Running Gear Bkt Assy (4) 209 479 Caster (4) Brackets MUST be installed onto rack before installing casters. 601 965 Screw 375-16x1.00 Hex (32) Screws and nuts MUST be installed as shown.
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Page 21: Section 3 - Maintenance & Troubleshooting
SECTION 3 – MAINTENANCE & TROUBLESHOOTING 3-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Torch Body Cracked Unreadable Cables Labels Repair Or Replace Cracked Cables And Cords Clean Tighten Weld... -
Page 22: Overload Protection
3-2. Overload Protection Control Box Location Of 3-Phase Fuse Block Each Power fuse block protects the welding power source connected to it from overload. 3-Phase Fuse Block Fuses If fuse(s) in fuse block open(s), the matching welding power source shuts down. To check fuse block, place line disconnect switch in Off position and open hinged fuse holder on applicable fuse block to... -
Page 23: Troubleshooting
3-3. Troubleshooting Trouble Remedy No weld output from any welding Place line disconnect switch in On position (see Section 2-8). power sources; units completely inoperative. Check and replace line fuse(s), if necessary, or reset circuit breakers (see Section 2-8). Check for proper input power connections to rack (see Section 2-8). No weld output from one welding Check fuses in applicable fuse block (see Section 3-2). -
Page 24: Section 4 - Electrical Diagrams
SECTION 4 – ELECTRICAL DIAGRAMS 208 333 Figure 4-1. Circuit Diagram For Control Panel In Racks Requiring 460/575 Volt Input Power For 1-4 CST 250 Models Or 230/460 Volt Input Power For 1-4 Maxstar 200 Models OM-2238 Page 20... -
Page 25: Section 5 - Parts List
SECTION 5 – PARTS LIST Ref. 803 531-A Figure 5-1. Dual Rack Kit Item Dia. Part Mkgs. Description Quantity Figure 5-1. Kit, Dual Rack ... . . 088 058 NUT, 500-13 locking .75 hex . - Page 26 Notes...
- Page 27 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 Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
- Page 28 Distributor Address City State 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...
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