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Miller Gold Star Series User Manual

Miller Gold Star Series
48 pages
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302, 452, 652 (60 Hz), 402, 602, 852 (50 Hz)
Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
OM-222 164 850AR
201207
Air Carbon Arc (CAC-A)
Cutting and Gouging
Flux Cored (FCAW) Welding
Arc Welding Power Source
Gold Star Series
Visit our website at
www.MillerWelds.com
File: Stick (SMAW)
CE and non-CE

Table of Contents

Questions and Answers:

Miller Gold Star Series Specifications

General IconGeneral
BrandMiller
ModelGold Star Series
CategoryWelding System
LanguageEnglish

Summary

Declaration of Conformity

Product and Apparatus Identification

Identifies specific Miller Gold Star series products and their stock numbers for compliance.

Council Directives

Lists EU directives like Low Voltage and EMC that the product complies with.

Standards

Lists relevant industry standards (IEC, EN) for product safety and electromagnetic compatibility.

Safety Precautions

Symbol Usage

Explains the meaning of danger, warning, and notice symbols used throughout the manual for hazard identification.

Arc Welding Hazards

Details risks of electric shock, fumes, fire, explosion, flying metal, gas buildup, EMF, noise, and cylinder handling.

Additional Safety Symbols and Maintenance Hazards

Covers hazards like fire, falling equipment, overheating, sparks, static discharge, battery explosions, and HF radiation.

California Proposition 65 Warnings

Warns about chemicals in fumes that may cause cancer or birth defects, advising hand washing after use.

Principal Safety Standards

Lists key safety standards (ANSI, NFPA, CSA) and regulatory bodies relevant to welding operations and safety.

EMF Information

Advises on electromagnetic fields (EMF) and potential interference with medical implants, recommending user precautions.

Installation

CE Product Information

Provides essential information for CE-marked products intended for sale and use within the European Union.

Electromagnetic Fields (EMF) Information

Details EMF assessment and usage guidelines for occupational environments, not for general public.

Electromagnetic Compatibility (EMC) Information

Addresses EMC compliance for Class A equipment and user responsibility regarding power supply connection requirements.

Serial Number and Rating Label Location

Specifies the location of the serial number and rating label for determining input power and output capabilities.

Specifications

Lists technical specifications including rated output, voltage, amperage, duty cycle, and input power requirements for various models.

Duty Cycle and Overheating

Explains duty cycle percentages and outlines steps to take if the unit overheats to prevent damage and maintain warranty.

Volt-Ampere Curves

Illustrates output voltage and amperage capabilities for different models and welding processes (SMAW, GTAW).

Selecting A Location

Provides guidance on choosing a suitable installation location, ensuring adequate airflow and proximity to power supply.

Dimensions and Weights

Details the physical dimensions and weight specifications for the 300, 450, and 650 Amp models.

Tipping Hazards

Warns against moving or operating the unit where it could tip, showing safe handling methods with lifting equipment.

115 VAC Receptacle and Protectors

Describes the 115 VAC receptacle and its associated supplementary protective devices for safe operation.

Weld Output Terminals

Identifies the electrode and work output terminals and provides guidelines for safe and correct cable connection.

Weld Output Terminals and Cable Sizes

Provides a chart for selecting appropriate weld cable sizes based on amperage, duty cycle, and total cable length.

Connecting Weld Output Cables

Illustrates correct and incorrect methods for connecting weld output cables to the unit's terminals for optimal performance.

Remote 14 Receptacle Information

Details the function of each socket in the Remote 14 receptacle for connecting remote controls and sensing signals.

Connecting Remote Control

Shows how to connect a remote control device to the unit's Remote 14 receptacle for external operation.

Electrical Service Guide

Offers recommendations for dedicated circuit sizing, fuse ratings, conductor sizes, and input power requirements.

Placing Jumper Links

Guides users on how to adjust jumper links to match the available input voltage at the job site for proper operation.

Connecting 3-Phase Input Power

Provides instructions and diagrams for safely connecting the welding unit to a 3-phase input power supply.

Operation

Controls (Non CE Models)

Explains the function and use of various controls on non-CE model Gold Star welding power sources for operation.

Controls (CE Models)

Details the operation of controls on CE model Gold Star welding power sources, highlighting differences from non-CE models.

Maintenance and Troubleshooting

Routine Maintenance

Outlines a schedule for checking, cleaning, and replacing components for regular upkeep and optimal performance.

Fuse F1

Explains the function of Fuse F1, its role in protecting components, and procedures for its replacement.

Troubleshooting

Offers solutions for common operational problems and unit malfunctions, guiding users through diagnostic steps.

Electrical Diagram

Parts List

Main Assembly

Lists components and hardware for the main assembly of the welding unit, referencing Figure 8-1.

Front Panel Components

Details the parts and components found on the front panel of the unit, referencing Figure 8-2.

Rectifier Assemblies

Lists components for the Si diode and SCR main rectifier assemblies, referencing Figures 8-3 and 8-4.

Rear Panel Components

Identifies the parts and components located on the rear panel of the unit, referencing Figure 8-5.

Warranty Information

Owner's Record and Service Contact

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