Miller GOLDSTAR 302 User Manual

OWNER’S
MANUAL
January 1996 Form: OM-222D
Effective With Serial No. KG054113
cover_om 4/95 − ST-800 168-B PRINTED IN USA
© 1996 MILLER Electric Mfg. Co.
Gold Star® 302, 452, 652 (60 HZ)
Gold Star® 402, 602, 852 (50/60 HZ - )
CC/DC Welding Power Sources For SMAW, GTAW Welding, And CAC-A Cutting And Gouging
Model
Rated
Welding
Amp
Range
Maximum
Open-
Circuit
IP
Rating
Amperes Input at Rated Load Output, 50 or 60 Hz,
Three-Phase
Model
Welding
Output
Range
DC
Circuit
Voltage
DC
R
a
ti
ng
200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
300
Amp
300 A @
32 Volts
DC, 60%
Duty Cycle
15 − 395
72
(70)
21M __
61
3.6*
35
1.1*
33
1.1*
31
1.0*
31
3.1*
25
1.5*
24.5
1.3*
13.8
0.67*
450
Amp
450 A @
38 Volts
DC, 60%
Duty Cycle
20 − 590
72
(70)
21M
102
3.5*
89
3.1*
54
1.5*
51
1.4*
47
1.2*
45
1.5*
36
1.2*
35.5
1.2*
23.3
0.51*
650
Amp
650 A @
44 Volts
DC, 60%
Duty Cycle
50 − 850
72
(70)
21M −−
124
5.2*
75
1.7*
71
1.6*
65
1.5*
62
2.6*
50
2.1*
49.4
2.1*
36
0.58*
*While idling
( ) Indicates specification differences for CE models

Miller GOLDSTAR 302 Specifications

General

Brand	Miller
Model	GOLDSTAR 302
Category	Welding System
Language	English

Summary

Safety Precautions for Arc Welding

Symbol Usage

Explains the meaning of hazard symbols used throughout the manual for safety awareness.

Arc Welding Hazards

Details common hazards such as electric shock, noise, fumes, and arc rays during welding operations.

Additional Installation, Operation, and Maintenance Hazards

Covers hazards related to installation, operation, and maintenance, including fire, moving parts, and radiation.

Principal Safety Standards

Lists key safety standards and regulations relevant to welding and electrical equipment.

EMF Information and Health Considerations

Discusses electromagnetic fields (EMF) and their potential biological effects, advising caution.

Definitions and Symbols

Warning Label Definitions

Explains the meaning and significance of various warning labels and safety symbols found on the equipment.

Manufacturer's Rating Labels for CE Products

Describes the information and certifications present on rating labels for European Community (CE) products.

General Symbols and Definitions

Provides a comprehensive glossary of symbols and their corresponding definitions used in the manual.

Installation Guide

Selecting an Installation Location

Guidance on choosing a proper location for the welding power source, considering airflow and clearances.

Dimensions and Weights

Provides physical dimensions and weight specifications for different models of the welding power source.

Tipping Hazards

Important safety information regarding the risk of tipping when placing or moving the unit.

115 VAC Receptacle and Circuit Breakers

Details the function and protection provided by the 115 VAC receptacle and associated circuit breakers.

Weld Output Terminals and Cable Sizing

Instructions for connecting to weld output terminals and selecting appropriate weld cable sizes.

Remote Receptacle and Terminal Strip Information

Information regarding the remote receptacle and terminal strip for connecting external controls.

Connecting Remote Controls

Step-by-step instructions for properly connecting remote control devices to the power source.

Electrical Service Guide

Recommendations for input voltage, amperes, fuse/breaker ratings, and conductor sizes.

Input Power Connection and Jumper Link Setup

Guide for setting jumper links to match input voltage and connecting the power source.

Operating the Welding Power Source

Control Panel Overview

Description and function of the various controls located on the front panel of the unit.

Duty Cycle and Overheating Prevention

Explanation of duty cycle ratings and measures to prevent overheating during operation.

Maintenance and Troubleshooting

Routine Maintenance Schedule

Outlines recommended routine maintenance tasks and their intervals for optimal performance.

Fuse F1 Location and Replacement

Information on locating Fuse F1 and instructions for its replacement to protect internal components.

Troubleshooting Common Issues

A guide to diagnosing and resolving common problems encountered during operation.

Electrical Diagram

Circuit Diagram

Detailed electrical schematic illustrating the internal circuitry of the welding power source.

Parts List and Assembly Diagrams

Main Assembly Diagram and Parts

Exploded view of the main assembly with a detailed list of all components and their part numbers.

Front Panel Components Diagram

Illustration and list of components mounted on the front panel, including controls and connectors.

Rectifier Diagrams and Parts

Diagrams and parts lists for the Si Diode and SCR Main Rectifiers used in the unit.

Rear Panel Components Diagram

Illustration and list of components mounted on the rear panel, including fan and access door parts.

Options and Accessories

Remote Controls, Meters, and Mounting Options

Details on remote controls, digital meters, running gear, and cylinder rack options.

Cable Management, Cooling, and Protection

Information on cable holders, adapters, water cooling systems, air filters, and protection packages.

Hand, Foot, and Extension Controls

Describes hand controls, foot controls, and extension cables for remote operation.

Wire Feeder Options

Details on portable wire feeders compatible with GMAW/FCAW welding processes.