Miller Gold Star 140 Owner's Manual
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Miller Gold Star 140 Owner's Manual

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Gold Star 140
OM-189 115
September 1998
Effective with serial number:
S.N. 145844
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R

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Summary of Contents for Miller Gold Star 140

  • Page 1 OM-189 115 September 1998 Effective with serial number: S.N. 145844 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Gold Star 140 Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS The following terms are SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ..used interchangeably 1-1. Symbol Usage ..........throughout this manual: TIG = GTAW 1-2.
  • Page 4 Declaration of Conformity Manufacturer’s Name: MILLER Europe S.P.A. Manufacturer’s Address: Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Declares that this product: Gold Star Conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Directives: 89/336/EEC Low Voltage: 73/23/EEC...

  • 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.

  • 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 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input at Rated Load Output, Maximum Open- Rated Welding 50/60 Hz, Single-Phase Amp Range DC Amp Range DC Model Model Circuit Voltage Circuit Voltage IP Rating IP Rating Output 230 V 240 V 130 A @ 25 Volts DC, 60% Duty 5 –...

  • Page 10: Volt-Ampere Curve

    2-3. Volt-Ampere Curve Volt-ampere curve shows mini- mum and maximum voltage and amperage output capabilities of unit. Scan 2-4. Selecting A Location Rating Label Use rating label to determine input power needs. Line Disconnect Device Locate unit near correct input pow- er supply.

  • Page 11: Typical Connections

    2-5. Typical Connections A. Typical Stick (SMAW) Connections B. Typical TIG (GTAW) Connections 2-6. Weld Output Terminals And Selecting Cable Sizes 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)

  • Page 12: Electrical Service Guide

    2-7. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 102 (31) 111 (34) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) S-0092-J 2-8.

  • Page 13: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Power Switch Amperage Adjustment Control Turn control clockwise to in- crease amperage. Thermal Overload Pilot Light Light turns on if unit overheats. Allow cooling period. See Sec- tion 2-2. Weld Indicator Light SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1.

  • Page 14: Troubleshooting

    4-2. Troubleshooting Trouble Remedy No weld output; unit completely inop- Be sure Power switch is On (see Section 3-1). erative. Be sure line disconnect switch is On (see Section 2-8). Check line fuse(s) and replace if necessary (see Sections 2-8). Check for proper input power connections (see Sections 2-7 or 2-8).

  • Page 15: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM Figure 5-1. Circuit Diagram OM-189 115 Page 11...

  • Page 16: Section 6 - Selecting And Preparing Tungsten Electrode

    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 ♦...

  • Page 17: Safety Information About Tungsten

    6-2. Safety Information About Tungsten Y Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) at the grinder or wear an approved respirator. Read MSDS for safety information.

  • Page 18: Section 7 - Guidelines For Tig Welding (Gtaw)

    SECTION 7 – GUIDELINES FOR TIG WELDING (GTAW) 7-1. Positioning The Torch Y Grinding the tungsten elec- trode produces dust and flying sparks which can cause injury and start fires. Use local ex- haust (forced ventilation) at the grinder or wear an approved respirator.

  • Page 19: Positioning Torch Tungsten For Various Weld Joints

    7-3. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-189 115 Page 15...

  • Page 20: Section 8 - Parts List

    SECTION 8 – PARTS LIST Hardware is common and not available unless listed. Figure 8-1. Main Assembly OM-189 115 Page 16...
  • Page 21 Qty. Item Ref. Code 156002025 UR.0.0.13 156121006 UR.0.0.11 156006011 UR.0.0.12 PCB.3 Filter 057101005 VG.1.8 056126062 UR.0.0.7 656089027 UR.0.0.18 057014096 UR.0.3 956142266 056067157 MQ.0.0.1 000097922 BP.2.0.20 056059254 UR.1.0.1 116170002 UR.0.0.17 057098009 UR.0.2 056076207 UR.0.0.16 056159010 UR.0.0.14 16 PCB1+PCB2 058075003 UR.3 Main+Logic V.230 16 PCB1+PCB2 058075002 UR.4 Main+Logic...
  • Page 22 Notes...
  • Page 23 Effective January 1, 1999 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg.
  • Page 24 Phone: 414-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Miller Europe Italy Phone: 39 (0) 2982901  PRINTED IN USA 1999 Miller Electric Mfg. Co. 7/99...

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