Miller Gold Star Series Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Gold Star Series
  6. Owner's manual

Miller Gold Star Series Owner's Manual

Ce and non-ce arc welding power source
Hide thumbs
Table of Contents

Advertisement

Quick Links

Visit our website at
www.MillerWelds.com
Gold Star Series
CE and non-CE
302, 452, 652 (60 Hz), 402, 602, 852 (50 Hz)
OM-222
2012−07
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
R
File: Stick (SMAW)
164 850AR

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Gold Star Series and is the answer not in the manual?

Questions and answers

Related Manuals for Miller Gold Star Series

Summary of Contents for Miller Gold Star Series

  • Page 1 Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Arc Welding Power Source Gold Star Series CE and non-CE 302, 452, 652 (60 Hz), 402, 602, 852 (50 Hz) File: Stick (SMAW) Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 4: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • 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_2011−10 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 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-222 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 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 16 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Consult rating label for input power requirements. Safe34 2012−05 Read Owner’s Manual and inside labels for connection points and procedures. Í...

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperage Control/ Gas Tungsten Arc Shielded Metal Arc Amperes Panel Welding (GTAW) Welding (SMAW) Do Not Switch Temperature Arc Force (DIG) Percent While Welding Output Circuit Breaker Remote Volts Protective Earth...
  • Page 18 Notes TM-216 869 Page 14 Dynasty 350/700, Maxstar 350/700...

  • Page 19: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 20: Duty Cycle And Overheating

    4-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 21: Volt-Ampere Curves

    4-5. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. A. 300 Amp Model B. 450 Amp Model C. 650 Amp Model va_curve1 − 4/95 − 171 221 / 171 222 / 171 223 OM-222 Page 17...

  • Page 22: Selecting A Location

    4-6. Selecting A Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks Movement beyond opposite side of unit. Line Disconnect Device Locate unit near correct input pow- er supply. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 23: Dimensions And Weights

    4-7. Dimensions And Weights Dimensions 300 Amp Models 450 Amp Models 650 Amp Models 30 in. (762 mm) including lift eye 30 in. (762 mm) including lift eye 30 in. (762 mm) including lift eye 23 in. (585 mm) 23 in. (585 mm) 23 in.

  • Page 24: Tipping

    4-8. Tipping Do not move or operate unit where it could tip. 4-9. 115 VAC Receptacle And Supplementary Protectors Turn power before connecting to receptacle. 115 V 15 A AC Receptacle Power is shared between RC9 and Remote 14 receptacle RC8 (see Section 4-14).

  • Page 25: Weld Output Terminals And Selecting Cable Sizes

    4-11. Weld Output Terminals And Selecting Cable Sizes NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 26: Connecting Weld Output Cables

    4-12. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 803 778-B cable terminal and copper bar. Make Weld Cable Terminal Turn off power before connecting to sure that the surfaces of the weld cable weld output terminals. Copper Bar terminal and copper bar are clean.

  • Page 27: Connecting Remote Control

    4-14. Connecting Remote Control Remote 14 Receptacle RC8 Connect remote control to RC8. Ref. 800 101-D / 141 127-D OM-222 Page 23...

  • Page 28: Electrical Service Guide

    4-15. Electrical Service Guide 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 29: Placing Jumper Links

    4-16. Placing Jumper Links Disconnect and lockout/tag- out input power before installing or moving jumper links. Check input voltage available at site. Jumper Link Label Check label − only one is on unit. Jumper Links Move jumper links to match input voltage.

  • Page 30: Connecting 3-Phase Input Power

    4-17. Connecting 3-Phase Input Power = GND/PE Earth Ground IMPORTANT Input Contactor L1 (U) L2 (V) L3 (W) GND/ PE Earth Ground Tools Needed: 5/32 in. 3/8, 1/2 in. 3/8 in. input3 2012−05 − Ref. 803 766-C / 800 103-C / Ref. 801 116-A OM-222 Page 26...
  • Page 31 4-17 Connecting 3-Phase Input Power (Continued) applicable, use lugs of proper amperage Connect input conductors L1 (U), L2 (V) and Installation must meet all National capacity and correct hole size. L3 (W) to welding power source line and Local Codes − have only qualified terminals.

  • Page 32: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls (Non CE Models) 300 Amp Model Shown 165 596-G short arc length without sticking the electrode. Remote Amperage Control Switch Polarity Selector Switch (Optional On 50 For front panel control, place switch in Panel Set control at 0 for normal welding amperage.

  • Page 33: Controls (Ce Models)

    5-2. Controls (CE Models) 300 Amp Model Shown 173 450-E short arc length without sticking the electrode. Remote Amperage Control Switch Polarity Selector Switch (Optional On 50 For front panel control, place switch in Panel Set control at 0 for normal welding amperage. Hz Models) position.

  • Page 34: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 35: Troubleshooting

    6-3. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-17). erative. Check fuse F1, and replace if necessary (see Section 6-2). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-17). Check for proper input power connections (see Section 4-17).

  • Page 36: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-222 Page 32...
  • Page 37 218 518-C OM-222 Page 33...

  • Page 38: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 800 875-G Figure 8-1. Main Assembly (452 Model Illustrated) OM-222 Page 34...
  • Page 39 Quantity Model Item Diagram Part 302 452 652 marking Description 402 602 Figure 8-1. Main Assembly ....+179 430 PANEL, side ......... . .
  • Page 40 Quantity Model Item Diagram Part 302 452 652 marking Description 402 602 852 Figure 8-1. Main Assembly (Continued) ..TP1,2 . . . 175 405 THERMOSTAT, NC (Included w/T1) ..... . .
  • Page 41 33 10 800 876-G Figure 8-2. Panel, Front w/Components (452 Model Illustrated) Quantity Model Item Diagram Part 302 452 652 marking Description 402 602 852 Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 28) ..169 331 SWITCH, mode polarity (single deck) .
  • Page 42 Quantity Model Item Diagram Part 302 452 652 marking Description 402 602 852 Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 28) (Continued) ....236 227 PLATE, control lower .
  • Page 43 Item Diagram Part Quantity marking Description 175 070 Figure 8-3. Rectifier, Si Diode (302 Model) (Fig 8-1 Item 29) ..C7-12 ..048 420 CAPACITOR, cer disc .01uf 1000VDC ......
  • Page 44 Item Diagram Part Quantity marking Description Figure 8-5. Panel, Rear w/Components (Fig 8-1 Item 18) ....173 283 CHAMBER, plenum 14 in ........
  • Page 45 Notes...
  • Page 46 Notes TM-216 869 Page 42 Dynasty 350/700, Maxstar 350/700...
  • Page 47 LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...

  • Page 48: Options And Accessories

    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 2012 Miller Electric Mfg. Co. 2012−01...

This manual is also suitable for:

Gold star 302Gold star 452Gold star 652Gold star 402Gold star 602Gold star 852 ... Show all

Table of Contents

Save PDF