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Gold Star® Series

Gold Star® Series
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Processes Stick (SMAW) TIG (GTAW) Air Carbon Arc (CAC-A) Cutting and Gouging Flux Cored (FCAW) MIG (GMAW) Spray Transfer when using a Voltage-Sensing Wire Feeder Heavy Industrial Applications Steel Erection Pipe Welding Tank/Pressure Vessel Fabrication Maintenance/Repair Shipbuilding Construction Refineries Chemical Manufacturing Facilities Steel Manufacturing Facilities Foundries Quick Specs Gold Star® Series Stick Welding Power Source Issued Dec. 2010 • Index No. DC/8.1 Built-in arc control lets you get in tight without sticking the electrode. An electrode compensation circuit ensures consistent arc control performance regardless of the electrode size. Superior arc welding performance with Stick and TIG welding. Power efficient for exceptional value and return on your investment. Fan-On-Demand™ operates only when needed reducing noise, power consumption, and the amount of airborne contaminants pulled through the machine. The Power of Blue®. Power source is warranted for 3 years, parts and labor. Original main power rectified parts are warranted for 5 years. Input Power 3-Phase Power on all models Rated Output 302/402: 300 A at 32 VDC, 60% Duty Cycle 452/602: 450 A at 38 VDC, 60% Duty Cycle 652/852: 650 A at 44 VDC, 60% Duty Cycle Weight 302/402: 352 lb (160 kg) 452/602: 404 lb (183 kg) 652/852: 505 lb (229 kg) 115 VAC duplex receptacle provides 15 amps of auxiliary power. Hot Start™ makes it easy to start difficult Stick electrodes such as E-6010 and E-7018. Simple control panel features single range amperage adjustment. Provides easy, efficient operation. Optional digital meters for voltage and amperage. Large displays are easy to read, even at 30 ft (9.2 m). Line voltage compensation ensures consistent weld performance by keeping output power constant even if primary input power varies by ±10%. Gold Star 452/602 Power cord strain relief provided for your convenience at installation. Enclosed circuit boards provide additional protection from contaminants resulting in longer service life. Thermal overload protection light indicates power shutdown. Helps prevent machine damage if the duty cycle is exceeded or airflow is blocked. PC board protection prevents the wire feeder power or other stray voltages (less than 115 VAC) from harming the power source PC board. 14-pin receptacle provides quick, direct connection to Miller 14-pin remote controls and switches. Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Web Site www.MillerWelds.com Equipment Sales US and Canada Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX: 920-735-4125 Build your own system at MillerWelds.com/equiptoweld

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9 2 1 6 5 8 7 3 4 0 0 20 10 30 40 50 60 70 80 50 100 150 200 250 300 350 400 450 500 SMAW GTAW SMAW ARC FORCE MIN. MAX. SMAW ARC FORCE 200 MIN. MAX. 400 300 600 800 1000 1200 10 15 20 25 30 40 50 60 70 80 90 100 DC AMPS DC VOLTS VOLT/AMP CURVE CC % DUTY CYCLE WELDING AMPS DUTY CYCLE CHART RATED OUTPUT Performance Data 2 Control Panel Gold Star® 302/402 Specifications (Subject to change without notice.) 1. Arc Force (DIG) Control 2. Polarity Selector Switch* 3. Output Switch (Contactor) 4. Remote Amperage Control Switch 5. Hot Start Switch 6. Digital Meters (Optional) 7. Amperage Adjustment...

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9 2 1 6 5 8 7 3 4 200 400 300 600 800 1000 1200 10 15 20 25 30 40 50 60 70 80 90 100 % DUTY CYCLE WELDING AMPS DUTY CYCLE CHART VOLT/AMP CURVE CC RATED OUTPUT SMAW ARC FORCE SMAW GTAW ARC FORCE SMAW MIN MAX MIN MAX 0 100 200 300 400 500 600 700 0 20 10 30 40 50 60 70 80 DC AMPS DC VOLTS Performance Data Control Panel Gold Star® 452/602 Specifications (Subject to change without notice.) 1. Arc Force (DIG) Control 2. Polarity Selector Switch* 3. Output Switch (Contactor) 4. Remote Amperage Control Switch 5. Hot Start Switch 6. Digital Meters (Optional) 7. Amperage Adjustment Control 8. Power...

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4 SMAW GTAW SMAW ARC FORCE MAX. SMAW ARC FORCE MIN. MAX. MIN. 0 0 20 10 30 40 50 60 70 80 100 200 300 400 500 600 700 800 900 1000 200 400 300 600 800 1000 1200 10 15 20 25 30 40 50 60 70 80 90 100 DC AMPS DC VOLTS VOLT/AMP CURVE CC % DUTY CYCLE WELDING AMPS DUTY CYCLE CHART RATED OUTPUT Performance Data Control Panel Gold Star® 652/852 Specifications (Subject to change without notice.) 1. Arc Force (DIG) Control 2. Polarity Selector Switch* 3. Output Switch (Contactor) 4. Remote Amperage Control Switch 5. Hot Start Switch 6. Digital Meters (Optional) 7. Amperage Adjustment Control 8. Power...

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5 Genuine Miller Options Genuine Miller Accessories Digital Meters #300 359 Field For Gold Star models after serial # KG 283 595. Easy-to-install, front-panelmount, digital amp and volt meters. Air Filter Kit #042 939 Field Helps protect internal components from dust and dirt, reducing need for maintenance and providing extended service life. Ground Current Sensor #195 048 Field Disables power source if weld current is present on primary ground. Polarity Switch #043 314 Field For Gold Star 602 and 852. Allows operators to switch from DCRP or DCEN for TIG or Stick applications without...

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6 Genuine Miller Accessories (Continued) Remote Controls and Switches Remote On/Off Control #242 197 025 Allows you to turn your Gold Star on or off from a distance of 25 ft (7.6 m). This is especially useful if your power source is located up in a mezzanine. Connects to the power source’s terminal strip. RMLS-14 #129 337 Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momen tary con tact. Includes 26.5 ft (8 m) cord and 14-pin plug. RCC-14 Remote Contactor and Current Control #151 086 Side-to-side (east/west)...

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50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1. All CE models conform to the applicable parts of the IEC 60974 series of standards. Conforms with NEMA EW 1 “Electric Arc Welding Power Source,” Class I (100). Certified by Canadian Standards Association to both the Canadian and U.S. Standards. ** * Litho in USA Distributed by: Ordering Information Equipment and Options Stock No. Description Qty. Price Power Source Gold Star® 302 #903 373* 200-208/230/460 V, 60 Hz #903 398* 230/460/575 V, 60 Hz Gold Star® 402 #907 362** 380/400/440 V,...

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