Miller Gold SealTM Model 5000 User manual

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#~41uI14Ft~4S4IV1

-



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~.w

April

1993

Form:

OM-157

745

Effective

With

Serial

No.

KD398640

OWNERS

MANUAL

Gold

SealTM

Model

5000



Read

and

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.



Call

your

distributor

you

not

understand

the

directions.



CV/DC

Welding

Power

Source/Wire

Feeder



For

FCAW

Welding

GMAW

Welding

With

Optional

Gas

Valve



Rated

Output

Of 70

Amperes

Volts

DC,

20%

Duty

Cycle



Uses

115

VAC

Single-Phase

Input

Power



Motor

Overload

Protection



Basic

Model

Includes

Gun,

Standard

Model

Adds

Gas

Valve,

Deluxe

Model

Adds

Gas

Regulator/Flowmeter

Give

this

manual

the

operator.



For

help,

call

your

distributor



or:

MILLER

ELECTRIC

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

54912

414-734-9821

cover

8/92



ST.161

158

PRINTED

USA

J

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

EffectIve

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

werrenty

supersedes

sit

MILLER

warrentlas

end

eaclunive

with

other

gusrentees

warrenflea

espreseed

Implied.

al-

LIMITED

WARRANTYSubject

the

terms

end

conditions

below,

MILLER

Electric

Mlg.

Co.,

Appleton,

Wioconain,

werrents

its

original

retell

purcheser

thet

new

MILLER

equipment

sold

elfer

the

effective

dete

this

limited

werrenty

free

tects

meteriel

end

workmanship

the

time

shipped

MILLER.

THIS

WAR

RANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

IMPLIED,

INCLUDING

THE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within

the

werrenty

periods

listed

below,

MILLER

will

repeir

replece

eny

wer

rented

perle

components

thet

tell

due

such

defects

meteriel

workmanship.

MILLER

must

notified

writing

within

thirty

(30)

deys

such

detect

teiture,

which

time

MILLER

will

provide

instructions

the

werrenty

cleim

procedures

followed.

MILLER

shell

honor

werrenty

ctelme

werrented

equipment

listed

below

the

event

such

teilure

within

the

werrenty

time

periods.

All

werrenty

time

periods

stert

the

dete

thet

the

equipment

wee

delivered

the

originel

retell

purcheser,

end

ere

follows:

Yeers

Perts



Yeers

Lebor

Originel

mein

power

rectifiers

Yeers



Perts

end

Lebor

Treneformer/Rectilier

Power

Sources

Plesme

Arc

Cutting

Power

Sources



Semi-Autometic

end

Autometic

Wire

Feeders



Robots

Yeers



Perte

end

Lebor



Engine

Driven

Welding

Generet

ore

)NOTE:

Engines

werrented

eeperetely

the

engine

menufecturer.)

Yeer



Perte

end

Lebor

Motor

Driven

Guns



Process

Controllers



Water

Coolent

Systems



Unite

Grids



Spot

Welders

Loed Benko



SDX

Trenetormern

Running

Geer/Treilere

Field

Options

(NOTE:

Field

options

ere

covered

under

True

BIaenM

for

the

remeining

werrenty

period

the

product

they

ere

inatelled

in,

for

minimum

one

yeer



whichever

greeter.)

Months



Bell

eries

Deye



Perle

end

Lebor



MIG

Gune/TIG

Torches

Pleeme

Culling

Torches

Remote

Controls

Acceeeory

Kite

Replecement

Perle

MILLERS

True

BtuenM

Limited

Werrenty

shell

not

epply

to:

Iteme

furnished

MILLER,

but

menufectured

others,

such

engines

trede

ecceeeoriee.

These

items

ere

covered

the

menufeclurers

werrenty,

eny.

Coneumeble

components;

euch

contect

tips,

culling

nozzles,

contectore

end

releye.

Equipment

thet

hen

been

modified

eny

perty

other

then

MILLER.

equip

ment

thet

hee

been

improperly

inetelled,

improperly

opereted

mIsused

based

upon

induetry

etenderde,

equipment

which

hee

not hed

reeeonebte

end

neceeeery

meintenence,

equipment

which

hoe

been

used

for

operetlon

outside

the

epeciticetione

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIAtJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

THE

USE

AND

MAINTENANCE

WELDING

EOUIPMENT.

the

event

werrenty

claim

covered

this

werrenty.

the

eecluslve

remedies

shell

be,

MILLERS

option:

II)

repeir;

12)

replecement;

or,

where

euthorlzed

writing

MILLER

eppropriete

ceees,

)3)

the

reesoneble

cost

repelr

replece

ment

euthorized

MILLER

service

stetlon;

(4)

peyment

orcredlt

for

the

pur

chase

price

(less

reesonebte

deprecietion

besed

upon

ectuel

use)

upon

return

the

goode

customers

risk

end

espenee.

MILLERS

option

repeir

reptecement

will

FOB.,

Fectory

Appleton,

Wisconsin,

FOB.

MILLER

euthorlzed

ser

vice

facility

determined

MILLER.

Therefore

compensetion

reImburse

ment

for

transportation

costs

eny

kind

wilt

ellowed.

THE

EXTENT

PERMITTED

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT,

INDIRECt

SPECIAL,

INCIDENTAL

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

PROFIT).

WHETHER

BASED

CON

TRACT,

TORT

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

REPRESENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EOUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MtLLER.

Some

otetee

the

U.S.A.

not

allow

Ilmitetions

how

long

implIed

werrenty

lesto,

the

eaclusion

incidentel.

indirect.

opeciel

consequentlel

demeges,

the

ebove

limitation

eaciusion

may

not

apply

you.

This

werrenty

provides

spe

cific

legal

rights,

end

other

rights

may

available,

but

may

vary

from

state

state.

Canada,

legislation

some

provinces

provides

for

certain

additional

warranties

remedies

other

than

staled

herein.

and

the

entent

that

they

may

not

waived,

the

limitations

and

eaclusione

eat

out

abova

may

not

apply.

ThIs

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

available,

but

may

vary

1mm

province

province.



RECEIVING-HANDLING

Before

unpack)ng

equipment,

ChBCk

carton

for

any

damage

that

may

haVB

occurred

dUr)ng

shipment.

File

any

C)aimS

for

)oss

damage

with

the

delivering

carrier,

Assistance

for

filing

setthng

c)aims

may

obta)ned

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Mode)

Designation

and

Serial

Style

Number.

Use

the

following

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit.

The

information

located

the

rating

label

nameplate.

Model

_________

Serial

Style

No.

Date

Purchase

miller

5/92

ARC

WELDING

SAFETY

PRECAUTIONS



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

avoid

injury.



Learn

the

meaning

WARNING

and

CAUTION.

WARNING

ARC

WELDING

can

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

welding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

information

given

below

only

summary

the

complete

safety

information

that

will

found

the

Safety

Standards

listed

the

page.

Read

and

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

electrode

and

work

circuit

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

semiautomatic

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

improperly

grounded

equipment

hazard.

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers.

Disconnect

input

power

stop

engine

before

installing

servicing

this

equipment.

Properly

install

and

ground

this

equipment

according

its

Owners

Manual

and

national,

state,

and

local

codes.

Turn

oft

all

equipment

when

not

use.

not

use

worn,

damaged,

undersized,

poorly

spliced

cables.

not

wrap

cables

around

your

body.

Ground

the

workpiece

good

electrical

(earth)

ground.

10.

not

touch

electrode

while

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.

12.

Wear

safety

harness

prevent

falling

working

above

floor

level.

13.

Keep

all

panels

and

covers

securely

place.

/~p~

~2

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Wear

welding

helmet

fitted

with

proper

shade

filter

(see

ANSI

Z49.1

listed

Safety

Standards)

protect

your

face

and

eyes

when

welding

watching.

Wear

approved

safety

glasses.

Side

shields

recommended.

Use

protective

screens

barriers

protect

others

from

flash

and

glare;

warn

others

not

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

Use

approved

ear

plugs

ear

muffs

noise

level

high.

WARNING

CAUTION

Safety

Alert

Symbol

______________

ELECTRIC

SHOCK

can

kill



MOVING

PARTS

can

Injure.



not

touch

live

electrical

parts.

h

1…~I.



Keep

away

tram

moving

parts.



Disconnect

input

power

before

installing

servicing.

J~j



Keep

all

panels

and

covers

closed

when

operating.

SignalWord

WARNING

means

possible

death

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

equipment

damage

can

happen.

V

Statement

Hazard

And

Result

NOTE

READ

SAFETY

BLOCKS

start

_____

Section

3-1

before

proceeding.

Safety

Instructions

Avoid

Hazard

Turn

Off

switch

when

using

high

frequency.

Hazard

Symbol

(If

Available)

Safety

Banner

Read

safety

blocks

for

each

sym.

bol

shown.

NOTE

Special

instructions

for

best

oper

ation



not

safety.

FUMES

AND

GASES

can

hazardous

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

not

breath

the

fumes.

inside,

ventilate

the

area

and/or

use

exhaust

the

arc

remove

welding

fumes

and

gases.

ventilation

poor,

use

approved

air-supplied

respirator.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners.

Work

confined

space

only

well

ventilated,

while

wearing

air-supplied

respirator.

Shielding

gases

used

for

welding

can

displace

air

causing

injury

death.

sure

the

breathing

air

safe.

not

weld

locations

near

degreasing,

cleaning,

spraying

operations.

The

heat

and

rays

the

arc

can

react

with

vapors

form

highly

toxic

and

irritating

gases.

not

weld

coated

metals,

such

galvanized,

lead,

cadmium

plated

steel,

unless

the

coating

removed

from

the

weld

area,

the

area

well

ventilated,

and

necessary,

while

wearing

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

welded.

Chipping

and

grinding

cause

flying

metal.

welds

cool,

they

can

throw

off

slag.

PRINCIPAL

SAFETY

STANDARDS

Safety in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

33126

Safetyand

Health

Standards,

OSHA

CFR

1910,

from

Superintendent

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

Containers

That

Have

Held

Hazardous

Substances,

American

Welding

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

Safe

Handling

Compressed

Gases

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

22202.

Code

for

Safety in

Welding

and

Cutting,

CSA

Standard

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

ANSI

Standard

Z87.

,from

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

WELDING

can

cause

fire

explosion.

Watch

for

fire,

and

keep

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

electrode

orwelding

wire

aware

that

welding

ceiling,

floor,

bulkhead,

partition

can

cause

fire

the

hidden

side.

not

weld

closed

containers

such

tanks

drums.

metal

objects

can

cause

sparks,

overheating,

fire,

Connect

work

cable

the

work

the

welding

area as

practical

prevent

welding

currentfrom

traveling

long,

possibly

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

not

weld

where

flying

sparks

can

strike

flammable

material.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

not

use

welder

thaw

frozen

pipes.

Remove

all

flammables

within

(10.7

the

welding

arc.

this

not

possible,

tightly

cover

them

with

approved

covers,

10.

Remove

stick

electrode

from

holder

cut

off

welding

wire

contact

tip

when

not

use.

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wearoil-free

protective

garments

such

leather

gloves,

heavy

easily

through

small

cracks

and

openings

adjacent

areas,

shirt,

cuffless

trousers,

high

shoes,

and

cap.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury,

Wear

approved

face

shield

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

protect

skin.

CYLINDERS

can

explode

damaged.

Keep

cylinders

away

from

any

welding

other

electrical

circuits.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

damaged,

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

the

welding

process,

sure

treat

them

carefully.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

Never

allow

welding

electrode

touch

any

cylinder.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

good

condition.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

Keep

protective

cap

place

over

valve

except

when

cylinder

use

connected

for

use.

Install

and

secure

cylinders

upright

position

chaining

Read

and

instructions

compressed

gas

cylinders,

them

stationary

support

equipment

cylinder

rack

associated

equipment,

and

CGA

publication

P-i

listed

Safety

prevent

falling

tipping.

Standards.

Cutting

And

Welding

Processes,

NFPA

Standard

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

TABLE

CONTENTS

SECTION



SPECIFICATIONS

1-1.

Volt-Ampere

Curve

And

Duty

Cycle

Chart

SECTION

2INSTALLATION

2-1.

Installing

Work

Clamp

2-2.

Gun

Polarity

For

Wire

Type

2-3.

Installing

Welding

Gun

2-4.

Connecting

Input

Power

2-5.

Threading

And

Feeding

Welding

Wire

2-6.

Installing

Gas

Supply

SECTION

3OPERATION

SECTION

MAINTENANCE

TROUBLESHOOTING

4-1.

Overload

Protection

4-2.

Drive

Assembly

Maintenance

4-3.

Gun

Maintenance

4-4.

Troubleshooting

SECTION

5

ELECTRICAL

DIAGRAMS

SECTION

6

PARTS

LIST

Figure

6-1.

Main

Assembly

Figure

6-2.

Drive

Assembly,

Wire

Figure

6-3.

GA-i

6C1

Gun

OM.1

745

4/93

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