Miller Gold Star 302 Owner'S Manual Download Page 1

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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

2012

−

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

Summary of Contents for Gold Star 302

Page 1: ...scription TIG GTAW Welding Stick SMAW Welding OM 222 164 850AR 2012 07 Air Carbon Arc CAC A Cutting and Gouging Flux Cored FCAW Welding Arc Welding Power Source Gold Star Series Visit our website at w...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...ON 15 4 1 Important Information Regarding CE Products Sold Within The EU 15 4 2 Serial Number And Rating Label Location 15 4 3 Specifications 15 4 4 Duty Cycle And Overheating 16 4 5 Volt Ampere Curve...

Page 4: ...5 EC Low Voltage 2004 108 EC Electromagnetic Compatibility Standards IEC 60974 1 2005 Arc Welding Equipment Welding Power Sources IEC 60974 10 2007 Arc Welding Equipment Electromagnetic Compatibility...

Page 5: ...gs or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the...

Page 6: ...anks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as g...

Page 7: ...ARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maint...

Page 8: ...ion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health...

Page 9: ...ande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D autres consignes de s curit sont n cessaires dans...

Page 10: ...laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer l...

Page 11: ...rieur Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l...

Page 12: ...ulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les i...

Page 13: ...Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Regi...

Page 14: ...OM 222 Page 10...

Page 15: ...k by insulating yourself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation...

Page 16: ...office or your local distributor for further information Safe37 2012 05 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear comp...

Page 17: ...Welding Arc Force DIG Percent Output Circuit Breaker Remote V Volts Protective Earth Ground Positive Negative Input On Off Hz Hertz Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U...

Page 18: ...TM 216 869 Page 14 Dynasty 350 700 Maxstar 350 700 Notes...

Page 19: ...d disturbances This equipment complies with IEC 61000 3 12 provided that the short circuit power Ssc is greater than or equal to 3 724 420 at the interface point between the user s supply and the publ...

Page 20: ...t 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 NOTICE Exceed...

Page 21: ...es Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown B 450 Amp Model C 650 Amp Model A 300 Amp Model va_...

Page 22: ...using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liqu...

Page 23: ...775 mm including strain relief 38 in 966 mm including strain relief 38 in 966 mm including strain relief D 27 1 2 in 699 mm 35 in 889 mm 35 in 889 mm E 3 4 in 19 mm 1 1 4 in 32 mm 1 1 4 in 32 mm F 21...

Page 24: ...entary Protector CB1 3 Supplementary Protector CB2 CB1 protects the 115 volts ac por tion of RC8 and RC9 from overload CB2 protects the 24 volts ac portion of RC8 Press button to reset protector 1 3 2...

Page 25: ...0 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120...

Page 26: ...d 3 4 in 19 mm 4 2 3 1 5 6 connecting weld output cables 3 2010 4 13 Remote 14 Receptacle Information Socket Information 24 VOLTS AC A 24 volts AC Protected by supplementary protector CB2 B Contact cl...

Page 27: ...OM 222 Page 23 4 14 Connecting Remote Control Ref 800 101 D 141 127 D 1 Remote 14 Receptacle RC8 Connect remote control to RC8 OR OR A J B K I C L N H D M G E F 1...

Page 28: ...able 310 15 B 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Failure to follow these electrical service guide...

Page 29: ...r Link Label Check label only one is on unit 2 Jumper Links Move jumper links to match input voltage Close and secure access door or go on to Section 4 17 Tools Needed 2 1 Do not overtighten jumper li...

Page 30: ...g 3 Phase Input Power input3 2012 05 Ref 803 766 C 800 103 C Ref 801 116 A 3 8 1 2 in 3 8 in Tools Needed IMPORTANT GND 3 PE Earth Ground Input Contactor L1 U L2 V L3 W GND PE Earth Ground 8 5 4 2 11...

Page 31: ...Ground Current Sensor Optional Connect green or green yellow grounding conductor to welding power source ground ing terminal first If unit is equipped with op tional ground current sensor route groun...

Page 32: ...rn clockwise to increase short circuit amperage 3 Hot Start Switch Turn switch On for SMAW and Off for GTAW welding 4 Amperage Adjustment Control 5 Digital Meters Optional 6 Power Switch With Indicato...

Page 33: ...to increase short circuit amperage 3 Hot Start Switch Turn switch On for SMAW and Off for GTAW welding 4 Amperage Adjustment Control 5 Digital Meters Optional 6 Power Switch With Indicator Light 7 Hi...

Page 34: ...ry Authorized Service Agent Every 3 Months Labels Weld Terminals Every 3 Months Cables And Cords Every 6 Months During heavy service clean monthly 6 2 Fuse F1 Ref 800 101 C Turn Off power before open...

Page 35: ...ower switch pilot light on fan off Check for proper input power connections see Section 4 17 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 17 Have Factory Authorize...

Page 36: ...OM 222 Page 32 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 37: ...OM 222 Page 33 218 518 C...

Page 38: ...PARTS LIST 800 875 G Hardware is common and not available unless listed 1 2 3 4 7 6 8 9 10 11 12 13 18 Fig 8 5 14 15 16 17 19 20 21 22 3 4 23 24 27 28 Fig 8 2 29 Fig 8 3 4 22 5 Figure 8 1 Main Assemb...

Page 39: ...264 TRANSFORMER control 110VA 24V 380 400 440 50Hz 1 14 TE1 159 244 PRIMARY BOX includes 1 1 1 15 601 835 NUT 10 32 brs 24 24 24 16 038 887 STUD pri bd brs 10 32 x 1 375 24 24 24 010 913 WASHER flat...

Page 40: ...rectifier 2 2 2 28 Fig 8 2 PANEL front w components 1 1 1 29 SR1 175 070 RECTIFIER si diode Fig 8 3 1 29 SR1 192 672 RECTIFIER SCR main Fig 8 4 1 29 SR1 192 671 RECTIFIER SCR main Fig 8 4 1 When order...

Page 41: ...CIRCUIT CARD control 50HZ 1 2 PC1 231 163 CIRCUIT CARD control 50HZ 1 PLG1 158 720 CONNECTOR SOCKETS see Figs 8 3 8 4 PLG3 169 240 CONNECTOR SOCKETS 1 1 1 PLG5 152 249 CONNECTOR SOCKETS 1 1 1 3 CR3 0...

Page 42: ...l number 1 1 1 26 S2 159 039 SWITCH rocker SPDT 15A 125VAC 1 1 1 PLG2 185 626 CONNECTOR body 56 series 1 1 1 27 PL2 159 522 LED yellow 1 1 1 28 159 036 LENS LED clear 1 1 1 29 171 007 KNOB pointer 1 1...

Page 43: ...are is common and not available unless listed 1 2 3 4 5 6 Quantity Diagram marking Item No Part No Description SR1 Figure 8 4 Rectifier SCR Main 452 652 Model Fig 8 1 Item 29 192 672 192 671 1 C7 12 0...

Page 44: ...ock input connection CE models only 1 8 124 274 BRACKET mtg fan motor 1 9 R3 097 459 RESISTOR WW fxd 375W 20 ohm 1 10 FM 237 398 MOTOR 1 12HP 230V 1550RPM 50 60Hz 83A 1 800 707 F Hardware is common an...

Page 45: ...Notes...

Page 46: ...TM 216 869 Page 42 Dynasty 350 700 Maxstar 350 700 Notes...

Page 47: ...ontrols and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils...

Page 48: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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