Miller Electric | 452 | A DC8-1 Gold Star Series_A Gold Star Series.qxd

Gold Star Series
Issued Dec. 2010 • Index No. DC/8.1
®
Quick
Specs
Heavy Industrial Applications
Processes
Steel Erection
Pipe Welding
Tank/Pressure Vessel Fabrication
Maintenance/Repair
Shipbuilding
Construction
Refineries
Chemical Manufacturing Facilities
Steel Manufacturing Facilities
Foundries
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
Stick Welding
Power Source
Input Power
Rated Output
3-Phase Power on all models
Weight
302/402: 352 lb (160 kg)
452/602: 404 lb (183 kg)
652/852: 505 lb (229 kg)
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
The Power of Blue .
®
Build your own system at
MillerWelds.com/equiptoweld
Superior arc welding performance
with Stick and TIG welding.
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.
Optional digital meters for voltage
and amperage. Large displays are easy
to read, even at 30 ft (9.2 m).
Simple control panel features single
range amperage adjustment. Provides
easy, efficient operation.
Hot Start makes it easy to start
difficult Stick electrodes such as
E-6010 and E-7018.
™
14-pin receptacle provides quick,
direct connection to Miller 14-pin
remote controls and switches.
Line voltage compensation ensures
consistent weld performance by
keeping output power constant even if
primary input power varies by ±10%.
Enclosed circuit boards provide
additional protection from contaminants
resulting in longer service life.
Power efficient for exceptional value
and return on your investment.
Gold Star 452/602
115 VAC duplex receptacle provides
15 amps of auxiliary power.
Thermal overload protection light
indicates power shutdown. Helps
prevent machine damage if the duty
cycle is exceeded or airflow is blocked.
Fan-On-Demand™ operates only when needed
reducing noise, power consumption, and the amount
of airborne contaminants pulled through the machine.
PC board protection prevents the wire
feeder power or other stray voltages
(less than 115 VAC) from harming the
power source PC board.
Power cord strain relief provided for
your convenience at installation.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
Gold Star 302/402 Specifications
®
Rated Output
300 A at 32 VDC,
60% Duty Cycle
(Subject to change without notice.)
Amperage
Range
Amps Input at Rated Output, 50/60 Hz
200 V 230 V 380 V 400 V 440 V 460V 575 V KVA KW
Max. OpenCircuit Voltage
15–395 A
70
72 VDC
61
35
33
31
31
25
24.5 13.8
Net
Weight
Dimensions
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 30-1/2 in (775 mm)
including strain relief
352 lb
(160 kg)
Control Panel
1
5
2
6
7
3
8
4
9
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 Switch with Indicator Light
9. High Temperature Shutdown Light
*Note: Polarity Selector Switch is not standard on 402 model.
Performance Data
DUTY CYCLE CHART
RATED OUTPUT
1200
80
1000
70
800
60
600
50
DC VOLTS
WELDING AMPS
VOLT/AMP CURVE CC
400
SMAW
GTAW
40
SMAW
ARC FORCE
30
SMAW
ARC FORCE
20
300
10
200
15
20
25 30
40
% DUTY CYCLE
2
MIN.
0
10
50 60 70 80 90 100
0
50
MIN.
MAX.
100
150
200
250
DC AMPS
MAX.
300 350
400
450
500
Gold Star 452/602 Specifications
®
Rated Output
450 A at 38 VDC,
60% Duty Cycle
(Subject to change without notice.)
Amperage
Range
Amps Input at Rated Output, 50/60 Hz
200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
20 – 590 A
102
72 VDC
89
54
51
47
45
36
35.5 23.3
Net
Weight
Dimensions
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 38 in (966 mm)
including strain relief
404 lb
(183 kg)
Control Panel
1
5
2
6
7
3
8
4
9
1.
2.
3.
4.
5.
Arc Force (DIG) Control
Polarity Selector Switch*
Output Switch (Contactor)
Remote Amperage Control Switch
Hot Start Switch
6.
7.
8.
9.
Digital Meters (Optional)
Amperage Adjustment Control
Power Switch with Indicator Light
High Temperature Shutdown Light
*Note: Polarity Selector Switch is not standard on 602 model.
Performance Data
DUTY CYCLE CHART
1200
80
1000
70
800
60
600
50
DC VOLTS
WELDING AMPS
VOLT/AMP CURVE CC
RATED OUTPUT
400
SMAW
GTAW
40
SMAW
ARC FORCE
20
300
SMAW
ARC FORCE
30
10
200
MIN
0
10
15
20
25 30
40
% DUTY CYCLE
50 60 70 80 90 100
0
100
MIN
MAX
200
300
400
MAX
500
600
700
DC AMPS
3
Gold Star 652/852 Specifications
®
Rated Output
650 A at 44 VDC,
60% Duty Cycle
(Subject to change without notice.)
Amperage
Range
Amps Input at Rated Output, 50/60 Hz
230 V 380 V 400 V 440 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
50–850 A
124
72 VDC
75
71
65
62
50
49.4 36
Net
Weight
Dimensions
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 38 in (966 mm)
including strain relief
505 lb
(229 kg)
Control Panel
1
5
2
6
7
3
8
4
9
1.
2.
3.
4.
5.
Arc Force (DIG) Control
Polarity Selector Switch*
Output Switch (Contactor)
Remote Amperage Control Switch
Hot Start Switch
6.
7.
8.
9.
Digital Meters (Optional)
Amperage Adjustment Control
Power Switch with Indicator Light
High Temperature Shutdown Light
*Note: Polarity Selector Switch is not standard on 852 model.
Performance Data
DUTY CYCLE CHART
1200
80
1000
70
800
60
600
50
DC VOLTS
WELDING AMPS
VOLT/AMP CURVE CC
RATED OUTPUT
400
SMAW
GTAW
40
SMAW
ARC FORCE
30
SMAW
ARC FORCE
20
300
10
MIN.
200
0
10
15
20
25 30
40
% DUTY CYCLE
4
50 60 70 80 90 100
0
100
MAX.
200
300
MIN.
400
500
DC AMPS
MAX.
600 700
800
900 1000
Genuine Miller Options
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.
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
removing cables.
Ground Current Sensor #195 048 Field
Disables power source if weld current is
present on primary ground.
Genuine Miller Accessories
Coolant Systems
2/0 Stick Cable Set (50 ft) #173 851
Consists of 50 ft (15.2 m) 2/0 electrode
cable with holder and 50 ft (15.2 m) work
cable with clamp. 350 A, 100% duty cycle.
HF-251D-1 High-Frequency Arc
Starter/Stabilizer #042 388
This portable 250 amp, 60% duty cycle unit
adds high frequency to the welding circuit
to help start the arc when using the TIG
(GTAW) process. Operates on 115 VAC
50/60/100 Hz. See Lit. Index No. AY 5.1.
For more information, see Miller Coolant
Systems Lit. Index No. AY/7.2.
Standard Running Gear #042 886
The large 10 in (254 mm) rear wheels and
5 in (127 mm) front casters on this running
gear provide excellent mobility on the shop
floor, making it easier to move the power
source around and over cables and cracks.
Very easy to install. Handles double as weld
cable holder.
Standard Cylinder Rack #042 887
Holds two cylinders. Only installs on
Standard Running Gear.
Process Control Selector #042 872
Allows you to easily change weld processes
from TIG to Stick without changing cables.
Can be used with any constant-current,
constant-voltage or multiprocess CC/CV
welding power source.
5
Genuine Miller Accessories
(Continued)
Remote Controls and Switches
Wire Feeders
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
momentary contact. 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) rotary-motion
fingertip control. Fastens to TIG torch using
two Velcro® straps. Allows complete current
and contactor control at operator’s fingertips.
Includes 26.5 ft (8 m) cord and 14-pin plug.
RCCS-14 Remote Contactor and Current
Control #043 688
Up-and-down (north/south) rotary-motion
fingertip control. Fastens to TIG torch using
two Velcro® straps. Great for applications
that require a finer amperage control.
Includes 26.5 ft (8 m) cord and 14-pin plug.
6
RHC-14 Hand Control*
#242 211 020 20 ft (6 m) cord
#242 211 100 100 ft (30.5 m) cord
Miniature hand control for remote current
and contactor control. Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes
cord and 14-pin plug.
*Custom lengths available in 5 ft increments up to
50 ft and 10 ft increments up to 100 ft.
RFCS-14 Foot Control #043 554
Foot current and contactor control.
Includes 20 ft (6 m) cord and
14-pin plug.
Extension Cables for 14-Pin Plugs to
14-Pin Sockets*
#242 208 025 25 ft (7.6 m)
#242 208 050 50 ft (15.2 m)
#242 208 080 80 ft (24.4 m)
Extension cables make a direct connection
between the power source and remote
control or 24 VAC wire feeder. No messy
splicing or adapting required.
*Custom lengths available in 5 ft increments up to
50 ft and 10 ft increments up to 100 ft.
SuitCase® X-TREME™ 8VS Wire Feeder
#951 181
SuitCase® X-TREME™ 12VS Wire Feeder
#951 184
Lightweight, voltage-sensing wire feeders
include secondary contactor, gas valve and
drive roll kit. See Lit. Index No. M/6.41.
Notes
7
Ordering Information
Equipment and Options
Stock No.
Description
Gold Star® 302
#903 373*
#903 398*
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
Qty.
Power Source
Gold Star® 402
#907 362**
380/400/440 V, 50 Hz w/CE
Gold Star® 452
#903 374*
#903 400*
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
Gold Star® 602
#907 363**
380/400/440 V, 50 Hz w/CE
Gold Star® 652
#903 402*
230/460/575 V, 60 Hz
Gold Star® 852
#907 364**
380/400/440 V, 50 Hz w/CE
Digital Meters
#300 359
Field. For models after serial # KG 283 595
Air Filter Kit
#042 939
Field
Ground Current Sensor
#195 048
Field
Polarity Switch
#043 314
Field. For Gold Star 602 and 852
#173 851
Consists of electrode cable with holder and work cable with clamp
#042 388
HF Arc Starter/Stabilizer. See Lit. Index No. AY/5.1
Stick Accessories
2/0 Stick Cable Set (50 ft)
Stick Electrodes
TIG Accessories
HF-251D-1
Torch, Tungsten and Consumables
Gas Cylinder, Gas Hose and Fittings
Remote Controls
Remote On/Off
#242 197 025
RMLS-14
#129 337
Rocker switch
RCC-14
#151 086
Fingertip control (side to side)
RCCS-14
#043 688
Fingertip control (up and down)
RHC-14
#242 211 020
#242 211 100
Hand control with 20 ft (6 m) cord
Hand control with 100 ft (30.5 m) cord
RFCS-14
#043 554
Extension Cables
Foot control
See page 6
Wire Feeders
SuitCase® X-TREME™ 8VS
™
SuitCase X-TREME 12VS
®
#951 181
See Lit. Index No. M/6.41
#951 184
See Lit. Index No. M/6.41
Miscellaneous
Process Control Selector
#042 872
Standard Running Gear
#042 886
Standard Cylinder Rack
#042 887
Coolant Systems
See Lit. Index No. AY/7.2
Primary Power Cable
Secondary Welding Cables
Work Cable and Clamp
Date:
*
**
Total Quoted Price:
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
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).
Distributed by:
Litho in USA
Price
Download PDF