Miller CST 280 Owner's Manual
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Miller CST 280 Owner's Manual

Arc welding power source with meter
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CST 280 And CST 280 VRD
With Meter
OM-258 035F
2015−08
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
File: Stick (SMAW)

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  • Page 1 OM-258 035F 2015−08 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source CST 280 And CST 280 VRD With Meter Visit our website at File: Stick (SMAW) 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.

  • Page 3: Table Of Contents

    ......... . 4-7. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model .
  • Page 4 TABLE OF CONTENTS SECTION 7 − MAINTENANCE AND TROUBLESHOOTING ........7-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • 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 injure. 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 12 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 13: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 14 OM-258 035 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Always connect green wire to supply grounding terminal, never to a line terminal.

  • Page 16: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 17: Environmental Specifications

    C. 208-230/400-460 Volts VRD Model* Welding Input Rated Welding Maximum Amperes Input At Rated Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Dimensions Weight Range Voltage 280 A @ 31.2 VDC, 36.0 34.0 19.8 17.5 14.0 10.2 35 % Duty Cycle 3-Phase 5-280 A...

  • Page 18: Stick (Smaw) Volt-Ampere Curves Cst 280 Model

    4-5. Stick (SMAW) Volt-Ampere Curves CST 280 Model Volt-ampere curves show minimum xx10 Stick VA Curves maximum voltage amperage output capabilities of welding power source. Curves of other settings fall between curves shown. xx18 Stick VA Curve Ref. 221 588-A 4-6.

  • Page 19: Stick (Smaw) Volt-Ampere Curves Cst 280 Vrd Model

    4-7. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model xx10 Stick VA Curves Volt-ampere curves show minimum maximum voltage amperage output capabilities of welding power source. Curves of other settings fall between curves shown. xx18 Stick VA Curve 4-8. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model...

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting a Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 21: Weld Output Terminals And Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 5-3. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 22: Tig Lift-Arct Dcen (Direct Current Electrode Negative) Connections

    5-4. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections Positive (+) Weld Output Terminal Connect work lead to positive weld output terminal. Negative (−) Weld Output Terminal Connect TIG torch to negative weld output terminal. Gas Cylinder Cylinder Valve Open valve slightly so gas flow blows dirt from valve.

  • Page 23: Selecting 208 - 230 Volts Ac Single/Three Phase Input Voltage

    5-6. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage Turn Off welding power source, disconnect input power before proceeding. 208-230/400-460 Volts Model Check input voltage available at site. Switch Cover Voltage Selection Switch The input voltage that the power source is linked for is labeled next to the switch.

  • Page 24: Selecting 400 - 575 Volts Ac Three Phase Input Voltage

    5-7. Selecting 400 - 575 Volts AC Three Phase Input Voltage Turn Off welding power source, disconnect input power before proceeding. 208-230/400-460 Volts Model Check input voltage available at site. Switch Cover Voltage Selection Switch The input voltage that the power source is linked for is labeled next to 208−...

  • Page 25: Electrical Service Guide

    5-8. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 26: Connecting 1-Phase Input Power

    5-9. Connecting 1-Phase Input Power =GND/PE Earth Ground Tools Needed: Input1 2012−05 − Ref. 803 766-C / 258 649-A OM-258 035 Page 22...
  • Page 27 5-9. Connecting 1-Phase Input Power (Continued) See rating label on unit and check input Disconnect Device Grounding Terminal Installation must meet all National voltage available at site. and Local Codes − have only qualified Disconnect Device Line Terminals persons make this installation. Black And White Input Conductor (L1 Connect green or green/yellow grounding And L2)

  • Page 28: Connecting 3-Phase Input Power

    5-10. Connecting 3-Phase Input Power = GND/PE Earth Ground Tools Needed: Input2 2012−05 − Ref. 803 766-C / 258 649-A OM-258 035 Page 24...
  • Page 29 5-10. Connecting 3-Phase Input Power (Continued) See rating label on unit and check input volt- Connect green or green/yellow grounding Installation must meet all National age available at site. conductor to disconnect device grounding and Local Codes − have only qualified terminal first.

  • Page 30: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Output Indicator Light with the trailing decimal point illuminated. Green on nameplate indicates a TIG Measured amperage just prior to the end of function and Gray indicates a Stick When unit is first energized this indicator a welding operation will appear on the light flashes several times and then function.

  • Page 31: Process Select Control

    6-2. Process Select Control Process Select Control Rotate knob to select desired process. Lift-Arct TIG - Normal open-cir- cuit voltage is not present between the electrode and workpiece. A sol- id-state contactor does not ener- gize until after the electrode touches the workpiece, preventing overheating, sticking, or contamin- ating the electrode (see Section...

  • Page 32: Lift-Arc™ Start Procedure

    6-4. Lift-Arc™ Start Procedure Lift-Arc Start With Lift-Arct selected, start arc as follows: TIG Electrode Workpiece Turn gas on. Touch tungsten electrode to workpiece at weld start point. Hold electrode workpiece for 1-2 seconds, and Lift-Arc Start Method slowly lift electrode. Arc is formed when electrode is lifted.

  • Page 33: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before Maintain more often during severe maintaining. conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose...

  • Page 34: Troubleshooting

    7-3. Troubleshooting Output LED (Blue) High Temperature LED (Yellow) 258 649-A Repeated LED Flashes Indicate Status Display (LED1 Blue Yellow Trouble Possible Causes Remedy Code PC13) Place line disconnect switch in on Line Disconnect open. position (see Section 5-9 or 5-10). Check for proper input Improper input connections.
  • Page 35 7-3. Troubleshooting (Continued) Repeated LED Flashes Indicate Status Display (LED1 Blue Yellow Trouble Possible Causes Remedy Code PC13) Check Vfb leads for proper wiring Vfb leads not connected and connection to output studs and or reversed. PC13. Short circuit across output Check for shorts.
  • Page 36 PC2 LED Diagnosis (For PC Board 239 001 Or 245 857) Status Remedy Transformer T3 secondary voltage is up when lit. If not lit, contact factory authorized service (Secondary Power) agent. Status of precharge bus voltage and line voltage. If not lit, contact factory authorized service (Ready) Precharge should be completed when lit.
  • Page 37 Notes OM-258 035 Page 33...

  • Page 38: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram OM-258 035 Page 34...
  • Page 39 257 672-D OM-258 035 Page 35...

  • Page 40: Section 9 − Selecting And Preparing A Tungsten

    SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2013-10 Whenever possible and practical, use DC weld output instead of AC weld output. 9-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten Not all tungsten electrode manufacturers use the same colors to identify tungsten type.

  • Page 41: Section 10 − Guidelines For Tig Welding (Gtaw)

    SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) 10-1. Positioning The Torch 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.

  • Page 42: Torch Movement During Welding

    10-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.
  • Page 43 Notes OM-258 035 Page 39...

  • Page 44: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 258 650-B Figure 11-1. Main Assembly OM-258 035 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ... . . Fig 11-2 Panel, Front W/Cmpnt ..........
  • Page 46 ..{257907 Nameplate, Miller CST 280 w/Meter VRD .......
  • Page 47 Hardware is common and not available unless listed. 803 948-B Figure 11-3. Panel, Rear w/Components Item Part Description Quantity Figure 11-3. Panel, Rear w/Components ... . . 194242 Panel, Front/Rear .
  • Page 48 Hardware is common and not available unless listed. 804 206-B Figure 11-4. Magnetics Subassembly Item Dia. Part Mkgs. Description Quantity Figure 11-4. Magnetics Subassembly ... . . 206063 Panel, Plenum .
  • Page 49 Hardware is common and not available unless listed. 803 949-B Figure 11-5. Relinking Switch And Door Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-5. Relinking Switch And Door Assembly ... . +217252 Door Assy, Relinking .
  • Page 50 Hardware is common and not available unless listed. 803 159-E Figure 11-6. Heat Sink Assembly, Output Diode Item Diagram Part Quantity marking Description Figure 11-6. Heat Sink Assembly, Output Diode ... . . 205916 Heat Sink, Diode Output .
  • Page 51 Hardware is common and not available unless listed. 803 162-C Figure 11-7. Heat Sink Assembly, Input Item Diagram Part Quantity marking Description Figure 11-7. Heat Sink Assembly, Input ... . . 205915 Heat Sink, IGBT/Input Rectifier Module .
  • Page 52 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in.
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 Effective January 1, 2015 (Equipment with a serial number preface of MF or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 56 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2015 Miller Electric Mfg. Co. 2015−01...

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