Miller Gold Star 500SSX Owner'S Manual Download Page 1

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Summary of Contents for Gold Star 500SSX

Page 1: ...butor if you do not understand the directions Gold Starfi 500SSX CC DC Welding Power Source For SMAW and GTAW Welding 510 Amperes 41 Volts DC At 35 Duty Cycle Requires Three Phase 50 60 Hz Input Power...

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Page 3: ...or operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTE...

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Page 5: ...r muffs if noise level is high material wool and leather and foot protection FUMES AND GASES can be hazardous 5 Work in a confined space only if it is well ventilated or while to your health wearing a...

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Page 7: ...hen opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and...

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Page 9: ...st dangereux de respirer 1 Ecartez le visage pour viter de respirer les fum es 2 A lint rieur assurez vous que laire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es a larc...

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Page 11: ...les mains ou es cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux dentr...

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Page 13: ...periments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While mo...

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Page 17: ...NOTE D READ SAFETY BLOCKS at start of I _____ SectIon 3 1 berore proceeding Turn Off switch when using high frequency 4 Safety Instructions To Avoid Hazard 5 Hazard Symbol If Available 6 Safety Banne...

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Page 19: ...urves of other settings fall be tween the curves shown B High Range 70 60 50 40 0 30 C 20 10 0 70 60 50 40 0 30 C 20 10 0 0 50 100 150 2D0 250 300 350 400 450 500 650 600 DC AMPERES 0 100 200 300 400...

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Page 21: ...ry and equipment damage Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift the unit cwarnhil 3 93 Figure 3 1 Movement...

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Page 23: ...le length in weld circuit and maximum welding amperes Use Table 3 1 to select proper cable size Use shortest cables possible Do not use damaged cables 2 Terminal Lug Use lugs of proper amperage capaci...

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Page 25: ...3 0 1 210 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 4 4 0 1 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 4 4 0 1 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 3 3 0 3 4 0 4 4 0 4 4 0 We...

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Page 27: ...s ac contactor control circuit A AMPERAGE C D E 10 volts dc output to remote control Remote control ciircuit common 0 to 10 volts do input command signal from remote control The remaining sockets are...

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Page 29: ...bel 2 Input Terminal Board 3 Input Voltage Jumper Links Move links to match input voltage For example use 220 volts posi tion when 220 volts input power is available Reinstall top and side panel or go...

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Page 31: ...of NEC 4 The grounding conductorshall be colored or identified as specified in the NEC Grounding conductor size forcopperwire is not required to be larger than input conductor Article 250 95 of NEC R...

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Page 33: ...jury Keep away from moving parts Keep all doors panels covers and guards closed and securely in place MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation Pacemaker wearers keep away Wea...

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Page 35: ...r weld output place switch in On position For remote output control place switch in Remote 14 position see Section 3 4 Ref ST 168 257 1 Arc Force Control Dig This control is used for SMAW welding and...

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Page 37: ...Use switch to select way of control ling amperage adjustment For front panel control place switch in the Panel position For remote control place switch in Remote 14 position see Section 3 4 A AMPERM3...

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Page 39: ...tmeter displays voltage at the weld output terminals but not nec essarily the welding arc due to 2 cable resistance poor connec tions etc 2 Ammeter Ammeter displays weld amperage output of unit Insert...

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Page 41: ...inspecting maintaining or servicing HOT PAFITS can cause severe burns Allow cooling period before maintaining or servicing MOVING PARTS can cause injury Keep away from moving parts ance to be performe...

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Page 43: ...able 5 1 Welding Trouble Trouble Remedy Section Place line disconnect switch in the On position 3 5B Check for open line luse s and replace if necessary Check 3 5B and reset circuit breakers Check for...

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Page 45: ...weld connections Place Amperage control switch in the correct position Have Factory Authorized Service Station Service Distributor check control board PCi and or hall device HD1 Section 3 5B 3 3 Figu...

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Page 47: ...NOTES OM 168 256 Page 16...

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Page 49: ...SIECTION 6 ELECTRICAL DIAGRAMS u 0 I E U 0 Q g 0 LL SC 137 779 A w I U 0 0 Ui F 0 0 Figure 6 1 Circuit Diagram For Welding Power Source OM 168 256 Page 17...

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Page 51: ...GND Figure 6 2 Wiring Diagram For Welding Power Source GND OM 168 256 Page 18...

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Page 53: ...0 0 0 1 0 u cD z m 0 Cl C 4 1 4...

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Page 55: ...55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Upto25 Upto2O Uptol5 020 15 40 15 35 5 20 040 25 85 20 80 20 60 1 16 5...

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Page 57: ...gsten electrode only on grinderwith proper guards in a safe location wearing properface hand and body protection Keep f ammables away wam2 1 9 91 1 Tungsten Electrode 2 Tapered End Grind end of tungst...

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Page 59: ...0 0 0 1 0 0cD F r 2 4 11 C Im P a a a 3 a 25 Fig 8 5 21 Cl mC 0z Co ICl C I 19 I I 18 17 16 14 13 Fig 8 6 20...

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Page 61: ...C22 23 PCi RC1 PLG1 PLG2 137771 097 918 084553 4 281 058 972 048 280 058 971 035815 080 509 090 781 CAPACITOR BRACKET mtg terminal board CIRCUIT CARD root pass CONNECTOR w SOCKETS consisting of CONNEC...

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Page 63: ...l2hp 230V 1550rpm CHAMBER plenum 14 in BLADE fan 14 in 3wg 23cIeg 375 bore CCW PANEL rear ST 004 988 D 4 5 ST 136 574 038 138 Figure 8 3 Terminal Assembly Pri Fig 8 1 Item 8 Quantity 1 601 835 NUT br...

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Page 65: ...1 2 3 4 5 059 885 018606 045 546 081 008 027 878 Quantity 9 4 ST 080 214 B 4 5 6 7 8 5 Item Dia No Mkgs Part No Description ST 048 899 K SRi 140 121 Figure 8 5 Rectifiei SCR Fig 8 1 Item 21 Quantity 1...

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Page 67: ...0 0 0 010 uCD CD 1 0 n CD C ICD C D CD n 0 N C C CD Cl CD 3 0 N C I 0 I L__ N 9 6 N...

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Page 69: ...CH tgl SPST 20A 125VAC RESISTOR MF 25W 3 32K ohm 1 CONNECTOR w leads consisting of 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 CONNECTOR wTrERMINALS consi...

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Page 71: ...e this manual to the operator For help call your distributor Call ycur distributor if you do not understand the directions IJ or MILLER Electric Mfg Co P O Box 1079 Appleton WI 54912 414 734 9821 Mill...

Page 72: ...or operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIALINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTEN...

Page 73: ...screens or barriers to protect others from flash and glare warn others not to watch the arc 5 Wear protective clothing made from durable flame esistant material wool and leather and foot protection FU...

Page 74: ...02 Code for Safety in Welding and Cutting CSA Standard WI 17 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1 R3 Safe Practices For Occupation...

Page 75: ...un incendie ou une explosion Larc produit des tincelles ot dos projections Avoc Ia chaleur intense degagee par a tle et los mat riels elles peuvent causer un incondie et dos brlures Le contact axidon...

Page 76: ...es attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur protecteurs ou des capots pour faire lentretien ou le d pannage n cessaire 4 Pour emp ch...

Page 77: ...n biological systems While most of this work is of very high quality the results are complex Current scientific undeTstanding does not yet allow us to interpret the evidence in a single coherent frame...

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Page 79: ...AD SAFETY BLOCKS at start of Section 3 1 before proceeding Read safety blocks for each sym bol shown 7 NOTE NOTE Turn Off switch when using high frequency Special instructions for best oper ation not...

Page 80: ...of other settings fall be tween the curves shown B High Range 40 0 30 C a 20 10 0 C a 70 60 60 40 30 20 10 0 0 60 100 150 200 250 300 350 400 450 500 550 600 DC AMPERES 0 100 200 300 400 500 600 700 8...

Page 81: ...n be harmful Do not breathe welding fumes Place unit only where there is a good fresh air supply and proper ventilation FALLING EQUIPMENT can cause serious personal Injury and equipment damage Use lif...

Page 82: ...o work clamp or electrode hold er and weld output terminals 3 Insulated Electrode Holder 4 GTAW Torch Install according to manufacturers instructions For Example Total Cable Length In Weld Circuit 20...

Page 83: ...0 2 2 0 2 3 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 4 4 0 1 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 3 3 0 3 4 0 4 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density...

Page 84: ...s ac contactor control circuit A AMPERAGE C 0 E 10 volts dc output to remote control Remote control circuit common 0 to 10 volts dc input command signal from remote control The remaining sockets are n...

Page 85: ...right side panel to check jumper links 1 Input Voltage Label Look at jumper links and compare link position with unit label 2 Input Terminal Board 3 Input Voltage Jumper Links Move links to match inpu...

Page 86: ...of NEC 4 The grounding conductor shall be colored or identified as specified in the NEC Grounding conductor size for copper wire is not required to be larger than input conductor Article 250 95 of NEC...

Page 87: ...all doors panels covers and guards closed and securely in place r MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation Pacemaker wearers keep away Wearers should consult their doctor bef...

Page 88: ...or weld output place switch in On position For remote output control place switch in Remote 14 position see Section 3 4 1 Ref ST 168 257 1 Arc Force Control Dig This control is used for SMAW welding a...

Page 89: ...se switch to select way of control ling amperage adjustment For front panel control place switch in the Panel position For remote control place switch in Remote 14 position see Section 3 4 A AMPERS aE...

Page 90: ...utput terminals but not nec essarily the welding arc due to 2 cable resistance poor connec tions etc 2 Ammeter Ammeter displays weld amperage output of unit Install Select Put On Insert we __ Connect...

Page 91: ...specting maintaining or servicing HOT PARTS can cause severe burns S Allow cooling period before maintaining or servicing MOVING PARTS can cause injury Keep away from moving parts Maintenance to be pe...

Page 92: ...1 2 93 Table 5 1 Welding Trouble Trouble Remedy Section No weld output unit completely j Place line disconnect switch in the On position inoperative Check for open line fuse s and replace if necessar...

Page 93: ...ne current or line fuse s Check for proper input connections 3 5B opens repeatedly I ____________________________________________________ _____________ Check for proper juniper link positions 3 5A Che...

Page 94: ...NOTES OM 168 256 Page 16...

Page 95: ...SECTION 6 ELECTRICAL DIAGRAMS U 0 0 a 0 C q a 2 SC 137 779A w I I 0 0 0 U a C a Figure 6 1 CIrcuit Diagram For Welding Power Source CM i 68 256 Page 17...

Page 96: ...OM 168 256 Page 16 Figure 6 2 Wiring Diagram For Welding Power Source...

Page 97: ...0 0 0 N 010 D 0C 0 zm C In 9...

Page 98: ...200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 ThorIum Alloyed Tungsten Red Band 010 Up to 25 Up to 20 Upto 15 020 15 40 15 35 5 20 040 25 85 20 80 20 60 1 16...

Page 99: ...and start fires Shape tungsten electrode only on gnnder with proper guards in a safe location wearing properface hand and body protection Keep flammables away wam2 1 9 91 1 Tungsten Electrode 2 2 Tape...

Page 100: ...I 0 0 01a op3 a0 101 2 Fig 8 5 21 1 0 C Im S DP InU m B 0 C 23 Cl rnC 0z ICl Cl I Fig 8 3 10 I 171 16 11 15 14 13...

Page 101: ...R 1 1 1 C22 23 137 771 CAPACITOR 2 PCi RC1 PLG1 PLG2 097 918 084 553 i 4 281 058 972 048 280 058 971 035 815 080 509 090 781 BRACKET mtg terminal board CIRCUIT CARD root pass CONNECTOR w SOCKETS consi...

Page 102: ...R plenum 14 in BLADE fan 14 in 3wg 23deg 375 bore CCW PANEL rear 4 br ST 004 988 0 5 Item Part No No 7 6 Description Quantity 038 138 Figure 8 3 Terminal Assembly Pr Fig 8 1 Item 8 1 601 835 NUT brs h...

Page 103: ...t4 B 4 Figure 8 4 Switch PB Item Dia Part No Mkgs No 5 6 7 B 5 6 Figure 8 5 Rectifier SCR Description ST 048 899 K SRi 140 121 Figure 8 5 Rectifier SCR Fig 8 1 Item 21 Quantity 1 C7 12 048 420 CAPACIT...

Page 104: ...n a C ICD CD n I0 I C acD I 3 0 r C 0 A p C I N 1 0 F...

Page 105: ...skt push in 14 1 8ga Amp 66358 6 1 14 34 734 CONNECTOR circ 14 pin plug Amp 213571 2 134 731 CONNECTOR circ pin push in 14 l8ga Amp 213603 1 079 739 CONNECTOR circ damp str rlf Amp 206322 2 8 S2 4 011...

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