Miller Gold Star 500SSX Owner's Manual
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Miller Gold Star 500SSX Owner's Manual

Miller Gold Star 500SSX Owner's Manual

Miller owner's manual arc welding equipment 500ssx
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Miller
Apri
1994
Form:
OM-168
256
Effective
With
Serial No. KE600689
OWNERS
MANUAL
Read and follow these instructions
and all
safety
blocks
carefully.
Have
only
trained and
qualified
persons
install,
operate,
or
service this unit.
Call your distributor
if you do not understand
the directions.
Gold Starfi 500SSX
CC/DC
Welding
Power Source
For SMAW and GTAW
Welding
510
Amperes,
41 Volts
DC,
At 35%
Duty Cycle
Requires
Three-Phase,
50/60 Hz
Input
Power
Overheating
Protection
Arc
(Dig)
Control
Give this manual
to
the
operator.
For
help,
call your distributor
or:
MILLER Electric
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI 54912
414-734-9821
cover
1/94
ST-cOO 599-H
'
1994 MILLER
Electric
Mfg.
Co.
PRINTED IN USA

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Summary of Contents for Miller Gold Star 500SSX

  • Page 1 Call your distributor if you do not understand the directions. 1/94 ST-cOO 599-H cover Apri 1994 Effective With Gold Starfi 500SSX Power Source Welding 41 Volts At 35% Duty Cycle Three-Phase, 50/60 Hz Power Input Protection Control and all...
  • Page 3 MILLERS TRUE BLUETM LIMITED WARRANTY (Equipment This limited supersedes previous warranty LtMITED WARRANTY Subject terms coeditione Appleton, Wisconsin, warrants to original Mtg. sotd after the effective date of this MILLER equipment time it is shipped by tects in materiat workmanship OTHER RANTY IS EXPRESSLY...
  • Page 5 Connect work cable practical prevent unknown paths and hot metal. welder flammable material. Remove stick electrode from holder of the welding arc. when contact approved covers, welding Wear oil-free adjacent...
  • Page 7 (+ batteries. when removing over area cap. escape before completely removing cap.
  • Page 9 PRECAUTIONS MISE EN GARDE PROTEGEZ-VOUS, AINSI QUE LES AUTRES, ENFANTS NI LES PORTEURS DE STIMULATEUR CARDIAQUE SAPPROCHER, soudage, plupart des activitØs comme precautions. consignes de sØcuritØ suivantes respectez toutes ces normes. QUALIFIEES SEULES DES PERSONNES DESSAI. LELECTROCUTION peut dØcharge Olectrique peut brUler LØlectrode...
  • Page 11 ETINCELLES ET LES PROJECTIONS BRULANTES des blessures. causer piquage meulage produisent Les BOUTEILLES endommagees exploser. Les bouteilles contiennent des gaz Des bouteilles haute pression. C;omme les bouteilles font normalement exploser. procedØ traitez-les partie soudage, Les bouteilles doivent Œtre protegees chaleur intense, chocs arcs...

  • Page 13: Table Of Contents

    Considerations About NOTE ~ Magnetic following from the General Conclusions Section quotation of the U.S. Office of Technology Congress, Effects of Power Electric & Frequ9ncy OTA-BP-E-53 Background Paper, (Washington, Government Printing Office, May 1989): large volume of scientific findings based cellular level and from studies with animals and establish that low frequency magnetic...

  • Page 17: Safety Information

    SECTION Read all safety messages Obey safety messages WARNING and CAUTION. Learn thi? meaning kIII.~ ELECTRIC SHOCK not touch live electrical parts. Disconnect input before power installing servicing. -~_________ WARNIF~ NOTE Turn Off switch when SECTION Specifications Constant Current/Direct Currerlt Type Output Welding...

  • Page 19: Volt-Ampere

    2-1. Volt-Ampere Curves Range > DC AMPERES Duty Cycle 2-2. ~AUTION WELDING LONGER THAN RATED DUTY CYCLE rated load than shown below. weld longer Definition Duty Cycle minutes that unit rated load without At 510 Duly Cycle ii~ ~ 3-1/2 Welding Minutes OM-168 256...

  • Page 21: Installation

    SECTION A Location And 3-1. Selecting ~NARNING £~ ELECTRIC SHOCK not touch live electrical Disconnect power conductors from de input energized supply line BEFORE power source. FIRE OR EXPLOSION placing unit bustible t~urfaces. unit not iccate on, over, surfaces. install unit near BLOCKED AIRFLOW possible damage...

  • Page 23: Selecting

    NOTE LI~ii~ Overall dimensions 3-2. Overal :igure Arid 3-2. Selecting Preparing Tools Needed: Figure OM-168 256 Page include Front Dimensions And Base Mounting Weld Cables Output Total Cable Length Circuit 10 ft (3m) 3-3. Selecting Preparing Weld lifting handles, hardware, etc.
  • Page 24 -~-,...

  • Page 25: Connecting

    100 ft (30 m) Or Less 10 To 60% Welding 60 Thru 100% Cycle Duty Cycle Amperes Duty 2-2/0 2-2/0 2-2/0 2-3/0 1000 2-2/0 2-3/0 *Weld able size (AWG) is b ased either To Weld 3-3. Connecting Output ~JVARNING LECTRIC SHOCK touch live electrical Turn Off welding...

  • Page 27: Remote

    3-4. Remote 14 Receptacle > Table 3-2. Remote 14 Socket Information Socket* REMOTE OUTPUT (CONTACTOR) AMPERAGE *The remaining sockets not used. OM-168 256 Page Information And Connections 3-5. Remote 14 Connections Figure Socket Information 24 volts Contact closure completes 24 volts +10 volts dc to remote control.
  • Page 29 3-5. Connecting Input Power WARNING ELECTRIC SHOCK touch live electrical Do not Turn Off welding power source, persons install unit. Have only qualified Installation must meet National Electrical Code and Positioning Jumper Links VOLTS ~oo~ ~oo~ ~ oo~Oo oo~oo ~L1 'L2 'L3 ~ ~L~ 'L3 Tools Needed: 3/Biii...

  • Page 31: Connecting Input

    Connecting Input Power Tools Needed: 3/8 in 3/8 in Table 3-3. Electrical Input Voltage Input Amperes At Rated Output Recommended Standard Fuse Or Circuit Amperes1 Breaker Rating AWGIKcmII2 Conductor Size In Input Input Conductor Length In Feet AWGIKcmiI4 Grounding Conductor Size These values calculated from the 1993 edition of the National Electrical Code Recommended fuse...

  • Page 33: Operation

    SECTION WARNING ELECTRIC SHOCK kill. Always dry insulating gtoves. wear Insulate from work and yourself ground. touch live electrical parts. Keep panels securely covers FUMES AND GASES be hazardous your health. of the fumes. Keep ycur head Ventilate device. breathing area, or use Read Material...
  • Page 35 WARNING ELECTRIC SHOCK Do not touch live electrical touch weld output Do not touch electrode and work Weld output when switch is On and Power is On. \~J?~ (CONTACTOR) ~14~N Figure OM-168 256 Page kill. parts. terminals when contactor energized. clamp time same...
  • Page 37 RANGE SWITCH HIGH AMPERAGE PANEL Of Combinatloii Remote Example Amperage RANGE SWITCH HIGH AMPERM3E ~c~J O~NE1. G*OUTPUT (cONTACTOR) Set Switches Figure 4-7. Power Push Buttons Figure Control Amperage 4-6. Controls Amperage Adjustment Switch And Pilot Range Switch switch choose output range.
  • Page 39 ~JVARNING ARCING damago switch contacts. Switch while change Polarity position inside switch Arcing damage contacts, causing ~~~OLARITY (-)/%. ELECTRODE NEGATIVE DO NOT SWITCH UNDER LOAD Figure Select Install& Connect Electrode Equipment WeldiD Begin Figure 4-10. Connect~~ j)~1stall Install & & Connect High-Frequency Equipment...

  • Page 41: Maintenance & Troubleshooting

    SECTION MAINTENANCE & TROUBLESHOOTING ~WARNING ELECTRIC SHOCK tcuch live electrical Turn Off welding power power before input inspecting, maintaining, servicing. HOT PAFITS can cause severe Allow cooling period servicing. 5-1. Routine Maintenance Turn Off all power before maIntaInIng. kill. MOVING PARTS parts.

  • Page 43: Troubleshooting

    Overload Protection 5-2. WARNING ~-~ffIj When overheated, output stops, opens, keeps running. 5-3. Troubleshooting ~IVARNING ELECTRC SHOCK tcuch live electrical Turn Off welding power input power before inspecting, maintaining, servicing. HOT PARTS cause severe Allow cooling period before Trouble No weld unit completely output;...
  • Page 45 Trouble minimum weld output. Maximum weld output. I-.. Erratic weld output. Excessive line current line fuse(s) repeatedly. opens Fan motor inoperative and/or over- heating. Wandering poor control of arc; direction. Tungsten electrode oxidizing after conr~lusion of remaining bright weld. Remedy Check for proper lina voltage.
  • Page 47 NOTES OM-168 256 Page...
  • Page 49 SIECTION ELECTRICAL DIAGRAMS > > 6-1. Circuit Figure Diagram (.).~ ~. Q) Welding Power Source SC-137 779-A OM-168 Page...
  • Page 51 GND. GND. 6-2. Figure Wiring Diagram Welding Power Source OM-168 Page...
  • Page 53 -4 -.1 -4 0) 0) (1 0) -u...
  • Page 55 SECTION Foradditionalinformation, Wear clean 7-1. Selecting Tungsten Electrode Electrode Diameter Argon Negative/Straight Pure Tungsten (Green Band) .010 .020 5-20 .040 15-80 1/16 70-150 3/32 125-225 225-360 5/32 360-450 3/16 450-720 720-950 2% Thorium Alloyed Tungsten (Red Band) .010 Upto25 .020 15-40 .040 25-85...

  • Page 57: Preparing Tungsten

    7-2. Preparing TLungsten Figure 7-1. Preparing Tungsten ~AUTION LYING SPARKS AND HOT METAL Shapetur~gsten electrode only f(ammables away. Keep Electrode Diameter i~:::::/~~ Ideal Tungsten Preparation Wrong Tungsten Preparation Figure 7-2. Preparing Tungsten For AC Oir DC Electrode Positive injury can cause guards safe location grinderwith...
  • Page 59 F) r%) 0) 0) 1%) 0) -I Cl) z Co 25,~ P -~ C -Im (a, (a, 8 - 6...

  • Page 61: Main

    Dia. Part Item Mkgs. Figure 4~006 016 PANEL, 109 035 LABEL, COVER, top 006 017 026 627 GASKET, 004 214 BUSHING, 091 164 FRAME, 134 771 PLUG, STABILIZER 035 279 PANEL, 038 138 TERMINAL 137674 CAPACITOR CAPACITOR C22,23 137771 BRACKET, mtg 097 918 084553 CIRCUIT...

  • Page 63: Terminal

    Item Dia. Part Mkgs. Figure ..1...FM.. 116 190 MOTOR, CHAMBER, 032611 BLADE, 158 289 PANEL, Figure Rear 8-2. Panel, Part Item 038 138 Figure 8-3. Terminal 601 835 NUT, brs hex 10-32 038 058 TERMINAL .038887 STUD,priboardbrslo-32x1.375 WASHER, 010 913 flat brs .218 ID 038618 LINK,jumpertermbdpri...

  • Page 65: Rectifier

    Item Part 046 745 Figure 8-4. Switch, 059 885 BUTTON, push ..2... 018606 SPRING, cprsn .430 OD 3... 045 546 PUSH BUTTON 4... 081 008 BRACKET, mtg 5... 027 878 SWITCH, Jim leaf 1\~~ Figure 8-4. Switch, Item Dia. Part Mkgs.
  • Page 67 N) C~) CD Cl) CD 3 0) 0) 0) -u 1~) 0) ~?L__ I) 0 C -ICD...

  • Page 69: Panel

    Item Dia. Part Mkgs. Figure NAMEPLATE, POTENTIOMETER, 009 156 +158258 PANEL, SWITCH, 089085 084206 RESISTOR, CONNECTOR, 130257 143935 143934 143933 143936 143976 079 534 134734 CONNECTOR, 134731 CONNECTOR, CONNECTOR, 079 739 011609 SWITCH, S2,4... POTENTIOMETER, 072462 072590 SWITCH, 046745 CAPACITOR 04,5...
  • Page 71 Call ycur distributor if you do the directions. 1/94 ST-000 599-H cov& April 1994 Effective With Serial No. KE600689 Gold Starfi 500SSX Power Source Welding 41 Volts At 35% Duty Cycle Three-Phase, 50/60 Hz Input Power...
  • Page 72 Date of Purchase Effective 1. 1992 January with serial number preface MILLER marrasties is exclusive with other guarantees below. MILLER Electric Remote Controls retail purchaser that Accessory Kits limited tree of de warranty Replacement MILLER THIS WAR- T~ue MILLERS Blue Items furnished accessories.
  • Page 73 goggles.
  • Page 74 Allow engine when removing over...
  • Page 75 PRECAUTIONS E EN GARDE PROTEGEZ-VOUS, AINSI QUE LES AUTRES, ENFANTS SAPPROCHIER, LES PORTEURS DE STIMULATEUR CARDIAQUE soudage, plupart des activitØs industrielles, comme precautions. consignes de sØcuritØ suivantes respectez toutes nonnes. QUALIFIEES SEULES DES PERSONNES DOIVENT FAIRE DES DESSAI. LELECTROCUTlON peut dechargo electnquo peut bn~lergravement.
  • Page 76 ETINCELLES ET LES > PROJECTIONS BRULANTES des blessures. causer piquage et le meulage produisent Les BOUTEILLES endommagØes exploser. Les bouteilles contiennent des gaz haute Des bouteilles pression. Comme les bouteilles font normalement exploser. partie traitez-les procØdØ soudage, avec Les bouteilles doivent Œtre protØgØes chaleur intense,...
  • Page 77 22 24 24 25 25 26 NOTE ~ from the General Conclusions Section following quotation of the U.S. Congress, Offics of Effects of Power Frequency Background Paper, OTA-BP-E-53 Government Printing Officl3, volume of scientific findings large cellular level and from studi3s with animals and establish that low frequency magnetic produce changes...

  • Page 79: Safety Information

    SECTION Read all safety messages Obey safety messagos Learn the of WARNING and CAUTION. meaning ;i~ii~ieiI t~!~!f~ ELECTRIC SHOCK kill electctdai pacts. not touci live betorejj_4 Disconnect input power instsiling servicing. WA~~ NOTE Turn Off switch when SECTION Specifications Constant Current/Direct Current Type Output Welding...

  • Page 80: Volt-Ampere

    Curves 2-1. Volt-Ampere Range > DC AMPERES 2-2. Duty Cycle CAUTION WELDING LONGER THAN RATED DUTY CYCLE weld at rated load longer than shown below. Definition Duty Cycle minutes that unit rated load without Minutes Duty Cycle At 510 3-1/2 Minutes welding OM-168 256 Page...

  • Page 81: Selecting

    SECTION 3-1. Selecting A Location And WARNING ELECTRIC SHOCK not touch live electrical Disconnect input power BEFORE energized supply line power bource. FIRE O~R EXPLOSION placing unit over, bustible surfaces. locate unit on, over, surfaces. ~nstall unit flammables near BLOCK:ED AIRFLOW heating possible damage Dlock...
  • Page 82 NOTE ~ Overall dimensions 3-2. Overall Dim ensions And Base Figure 3-2. Selecting Preparing Tools Needed: Figure 3-3. OM-168 256 Page include lifting Front Mounting Weld Cables Output Example, Total Cable Length In Weld Circuit =20 ft Selecting Preparing Weld Output handles, hardware, etc.

  • Page 83: Connecting

    Total Cable 100 ft (30 m) Or Less 10 To 60% 60 Thru 100% Duty Cyclie Duty Cycle 2-2/0 2-2/0 2-2/0 2-3/0 2-2/0 2-3/0 Weld cable size (AWG) is b ased either 3-3. Connecting To Weld Output ~JVARNING LECTRIC SHOCK Do not touch live electrical Turn Off welding...

  • Page 84: Remote

    3-4. Remote Receptacle Table 3-2. Remote 14 Socket Information Socket* REMOTE ouTpuT (CONTACTOR) AMPERAGE remaining sockets used. OM-168 Page Information And Connections 3-5. Remote 14 Connections Figure Socket information 24 volts Contact closure to A completes 24 volts +10 volts dc control.
  • Page 85 3-5. Connectin~i Input Power WARNING ELECTRIC SHOCK not touch live electrical Turn Off welding source, power Have only qualified persons install unit. Installation must National Electrical Code and all other codes. meet Positioning Jumper Links 220 VOLTS ~oo~ ~oo~ t~oo~ oo~oo oo~OO oo~oo 'Li 'L2~L3 'L.f Tools Needed:...

  • Page 86: Connecting Input

    Connecting Input Power Tools Needed: 3/8 in 3/8 in Table 3-3. Input Voltage At Rated Input Amperes Output Recommended Standard Fuse Or Circuit Breaker Amperes Rating Input Conductor Size AWGJKcmiI2 Conductor in Feet Input Length AWG/KcmII4 Grounding Conductor Size In These values calculated from the 1993 edition of the National Electrical Code...

  • Page 87: Operation

    SECTION WARNING ELECTRIC SHOCK kill. insulating Always gloves. wear from work and Insulate yourself ground. touch live electrical parts. Keep panels securely covers FUMES AND GASES be hazardous your health. Keep your head of the fumes. VentilatEl breathing device. area, Read Material Safety Data Sheets...
  • Page 88 WARNING ELECTRIC SHOCK touch live electrical touch weld output touch electrode and work Weld output when switch Is On and Power Is On. tTh~. ~ (CONTACTOR) ~14~N Figure OM-168 256 Page kill. parts. terminals when contactor is energized. time clamp same terminals energized...
  • Page 89 RAN~ SWITCH AMPERN3E Example Of Cemblnatlcn Remote Amperage RAN~ swrrc~ HIGH AMPERS~aE ~c~JO~NEL G~L~~ (cONTPCTOR) Set Switches Figure Figure 4-7. Power Push Butl:ons Switch And Pilot Control Amperage 4-6. Amperage Adjustment Cont!ols Switch Range Use switch choose output range. gives better low amperage ad iustment (use with Low scale...
  • Page 90 WARNING ARCING damage switch contacts. change Polarity Switch position while Arcing inside switch damage contacts, ~:)/~ ELECTRODE NEGATIVE .---. DO NOT SWITCH UNDER LOAD Figure Install & Select Connect Electrode Equipment ________________ ______________ ______________ Welding Begin Figure 4-10. Install&Conneci\\ Install& Connect High-Frequency Unit...

  • Page 91: Maintenance

    SECTIONI MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK touch live electrical Turn Ofi welding power source, and disconnect pcwer before input inspecting, maintaining, servicing. HOT PARTS can cause severe Allow cooling period servicing. 5-1. Routine Maintenance Turn Off all power before maIntainIng.

  • Page 92: Overload Protection

    5-2. Overload Protection When overheated, output stops, opens, keeps running. 5-3. Troubleshooting WARNING ELECTRIC SHOCK touch live electrical Turn welding power inspecting, maintaining, input power before servicing. HOT PARTS can cause severe Allow cooling period before Trouble No weld unit output;...
  • Page 93 Trouble minimum weld output. Maximum weld output. Erratic weld output. Excessive line current line fuse(s) repeatedly. opens motor inoperative anc/or over- heating. Wandering poor control of arc; direction. i~ngsten electrode oxidizing after conclusion of remaining bright weld. Remedy Check for proper lino voltage.
  • Page 94 NOTES OM-168 256 Page...

  • Page 95: Electrical Diagrams

    SECTION 6- ELECTRICAL > CIrcuit Figure 6-1. Diagram DIAGRAMS ().~ Power Source Welding <U SC-137 779A CM-i 68 256 Page...
  • Page 96 Power Source 6-2. Welding Figure Wiring Diagram OM-168 256 Page...
  • Page 97 m C~) In 9 0) 0) N) 01 0) -D (0...

  • Page 98: Tungsten Electrode

    SECTION N OTE Foradditional Welding (GTAW) Wear clean .7-1. Selecting Tungsten Electrode Electrode Diameter Argon Negatlv&Stralght Polarity Pure Tungsten (Green Band) .010 to 15 .020 5-20 .040 15-80 1/16 70-150 3/32 125-225 225.360 5/32 360-450 3/16 450-720 720-950 ThorIum Alloyed Tungsten (Red Band) .010 to 25...

  • Page 99: Preparing Tungsten

    7-2. Preparing Tungsten ~iI~IjE~ Figur 7-i. Prepa ring Tungsten AUTION FLYING SPARKS AND HOT METAL Shape tungsten electrode only Keep flammables away. Electrode Diameter Ideal Tungsten Preparation Wrong Tungsten Preparation Figure 7-2. Preparing Tungsten 1-1/2 Times Electrode Diameter For AC Oi DC Electrode Po sitive injury can cause gnnder...
  • Page 100 Cl) rn C) 01 a) 10 1%) Cl) -I 1 (0 C -I m In U) m B...

  • Page 101: Main

    Item Dia. Part Mkgs. PANEL, 109 035 LABEL, ..2. COVER, top 006017 ..3. 026 627 GASKET, ..4. 004 214 BUSHING, ..5. 091 164 FRAME, PLUG, ..6. STABILIZER 035 279 ..7. PANEL, TERMINAL 038 138 ..9. 137674.. CAPACITOR ..9. C22,23 CAPACITOR 097 918 BRACKET~ mtg 084 553...

  • Page 102: Terminal

    Item Dia. Part Mkgs. Figure ..1...FM.. 116 190 MOTOR, 1/l2hp 131 361 CHAMBER, 032611 BLADE, 158289.. PANEL, Figure 8-2. Panel, Rear Item Part 038 138 Figure 8-3. Terminal NUT, brs hex 10-32 038 058 TERMINAL BOARD, 038 887 STUD, pri board brs 10-32 010 913 WASHER,...

  • Page 103: Switch

    item Part 046 745 Figure 8-4. Switch, 059 885 BUTTON, push 2... 018606 SPRING, cprsn .430 OD 3... 045 546 PUSH BUTTON 4... 081 008 BRACKEt mtg 5... 027 878 SWITCH, urn leaf 1\~~ ST-080 2t4-B Figure 8-4. Switch, Item Dia.
  • Page 104 r~) C.) cD (I, -n (a C -ICD...

  • Page 105: Panel

    Item Dia. Part Mkgs. Figure NAMEPLATE, 009 156 POTENTIOMETER, PANEL, 089 085 SWITCH, RESISTOR, 0134 206 1:30 257 CONNECTOR, LEAD 143 934 LEAD LEAD 143 933 143 936 LEAD 143 976 CONNECTOR 079 534 ,34 734 CONNECTOR, 134 731 CONNECTOR, 079 739 CONNECTOR, S2,4...

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