Miller Gold SealTM Model 5000 User manual

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April
1993
Form:
OM-157
745
Effective
With
Serial
No. KD398640
OWNERS
MANUAL
Gold SealTM
Model
5000

Read and follow these instructions and
all
safety
blocks
carefully.

Have
only
trained and
qualified
persons
install,
operate,
or
service this
unit.

Call
your
distributor if
you
do
not
understand
the
directions.

CV/DC
Welding
Power
Source/Wire
Feeder

For
FCAW
Welding
Or GMAW
Welding
With
Optional
Gas
Valve

Rated
Output
Of 70
Amperes
At
16
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
U
Give
this manual
to
the
operator.

For
help,
call
your
distributor

or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
cover
8/92

ST.161
158
PRINTED
IN
USA

J
U
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
EffectIve
January
1,
1992
(Equipment
with
a
serial number
preface
of KC
or
newer)
This limited
werrenty
supersedes
sit
previous
MILLER
warrentlas end
is
eaclunive
with
no
other
gusrentees
or
warrenflea
espreseed
or
Implied.
al-
LIMITED
WARRANTYSubject
to
the
terms
end
conditions
below,
MILLER Electric
Mlg.
Co.,
Appleton,
Wioconain,
werrents to
its
original
retell
purcheser
thet
new
MILLER
equipment
sold elfer the
effective dete of
this limited
werrenty
is
free of
de
tects
in
meteriel end
workmanship
et
the time
it
is
shipped
by
MILLER. THIS
WAR
RANTY IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE WARRANTIES
OF MERCHANTABILITY
AND
FIT
NESS.
Within the
werrenty
periods
listed
below,
MILLER will
repeir
or
replece
eny
wer
rented
perle
or
components
thet
tell
due
to
such
defects
in
meteriel
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
deys
of such
detect
or
teiture,
et
which
time
MILLER
will
provide
instructions
on
the
werrenty
cleim
procedures
to
be
followed.
MILLER shell honor
werrenty
ctelme
on
werrented
equipment
listed below
in
the
event
of
such
e
teilure
within the
werrenty
time
periods.
All
werrenty
time
periods
stert on
the dete
thet the
equipment
wee
delivered
to
the
originel
retell
purcheser,
end
ere es
follows:
t.
S
Yeers Perts

3
Yeers Lebor
Originel
mein
power
rectifiers
2. 3
Yeers

Perts end
Lebor
Treneformer/Rectilier
Power Sources
*
Plesme
Arc
Cutting
Power
Sources

Semi-Autometic
end Autometic
Wire Feeders

Robots
3.
2
Yeers

Perte end Lebor

Engine
Driven
Welding
Generet
ore
)NOTE:
Engines
em
werrented
eeperetely
by
the
engine
menufecturer.)
4.
1 Yeer

Perte
end
Lebor
*
Motor
Driven
Guns

Process
Controllers

Water
Coolent
Systems

HF 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
of the
product
they
ere
inatelled
in,
or
for
e
minimum
of
one
yeer

whichever
in
greeter.)
S. 6
Months

Bell eries
6.
90
Deye

Perle end
Lebor

MIG Gune/TIG
Torches
*
Pleeme
Culling
Torches
*
Remote Controls
4>
*
Acceeeory
Kite
*
Replecement
Perle
MILLERS
True
BtuenM
Limited
Werrenty
shell
not
epply
to:
1.
Iteme
furnished
by
MILLER,
but menufectured
by
others,
such
es
engines
or
trede
ecceeeoriee.
These items
ere
covered
by
the menufeclurers
werrenty,
If
eny.
2.
Coneumeble
components;
euch
en
contect
tips,
culling
nozzles,
contectore
end
releye.
3.
Equipment
thet
hen
been modified
by
eny
perty
other
then
MILLER.
or
equip
ment
thet
hee
been
improperly
inetelled,
improperly
opereted
or
mIsused
based
upon
induetry
etenderde,
or
equipment
which hee
not hed
reeeonebte
end
neceeeery
meintenence,
or
equipment
which hoe been
used
for
operetlon
outside of
the
epeciticetione
for the
equipment.
MILLER
PRODUCTS ARE
INTENDED
FOR PURCHASE
AND
USE
BY
COMMER
CIAtJINDUSTRIAL USERS AND PERSONS TRAINED
AND
EXPERIENCED
IN
THE
USE AND
MAINTENANCE OF WELDING
EOUIPMENT.
In
the
event
of
e
werrenty
claim covered
by
this
werrenty.
the
eecluslve remedies
shell
be,
et
MILLERS
option:
II)
repeir;
or
12) replecement;
or,
where euthorlzed
In
writing
by
MILLER
in
eppropriete
ceees,
)3)
the reesoneble
cost
of
repelr
or
replece
ment at
en
euthorized
MILLER service
stetlon;
or
(4)
peyment
of orcredlt for the
pur
chase
price
(less
reesonebte
deprecietion
besed
upon
ectuel
use)
upon
return
of the
goode
et
customers
risk end
espenee.
MILLERS
option
of
repeir
or
reptecement
will
be
FOB.,
Fectory
at
Appleton,
Wisconsin,
or
FOB.
et
e
MILLER
euthorlzed
ser
vice
facility
es
determined
by
MILLER.
Therefore
no
compensetion
or
reImburse
ment
for
transportation
costs
of
eny
kind
wilt
be
ellowed.
TO THE
EXTENT PERMITTED BY
LAW,
THE
REMEDIES PROVIDED HEREIN
ARE
THE SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECt SPECIAL,
INCIDENTAL OR CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT).
WHETHER
BASED ON
CON
TRACT,
TORT OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN AND ANY
IMPLIED
WAR
RANTY,
GUARANTY OR REPRESENTATION AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR BREACH OF
CONTRACT
TORT OR
ANY
OTHER LEGAL
THEORY
WHICH,
BUT FOR THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM OF
TRADE
OR
COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY MtLLER.
Some
otetee
in
the U.S.A. do
not
allow Ilmitetions of
how
long
en
implIed
werrenty
lesto,
or
the eaclusion of
incidentel. indirect.
opeciel
or
consequentlel
demeges,
so
the
ebove
limitation
or
eaciusion
may
not
apply
to
you.
This
werrenty
provides
spe
cific
legal
rights,
end other
rights
may
be
available,
but
may vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional warranties
or
remedies
other
than
as
staled
herein.
and
to
the
entent
that
they
may
not
be
waived,
the
limitations and eaclusione
eat out
abova
may
not
apply.
ThIs Limited
Warranty
provides
specific
legal rights,
and
other
rights
may
be
available,
but
may
vary
1mm
province
to
province.
 F
-
RECEIVING-HANDLING
Before
unpack)ng
equipment,
ChBCk
carton
for
any
damage
that
may
haVB
occurred
dUr)ng
shipment.
File
any
C)aimS
for
)oss
or
damage
with the
delivering
carrier, Assistance
for
filing
or
setthng
c)aims
may
be
obta)ned from distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information about
this
equipment,
always
provide
Mode)
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and Serial
or
Style
Number
of
your
unit.
The
information
is located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purchase
miller
5/92

ARC
WELDING SAFETY
PRECAUTIONS

Read all
safety
messages
throughout
this manual.

Obey
all
safety
messages
to
avoid
injury.

Learn the
meaning
of
WARNING and
CAUTION.
A~
WARNING
ARC WELDING
can
be
hazardous.
PROTECT YOURSELF
AND
OTHERS
FROM POSSIBLE
SERIOUS
INJURY
OR
DEATH. KEEP
CHILDREN
AWAY.
PACEMAKER WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain hazards
occurs.
Welding
is safe
when
precautions
are
taken. The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE ALL
INSTALLATION, OPERATION,
MAINTENANCE,
AND REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
Touching
live electrical
parts
can
cause
fatal
shocks
or severe
burns. The
electrode and work circuit
is
electrically
live whenever
the
output
is
on.
The
input
power
circuit and machine internal
circuits
are
also
live when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive roll
housing,
and all metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch live electrical
parts.
2.
Wear
dry,
hole-free
insulating gloves
and
body protection.
3. Insulate
yourself
from
work and
ground
using dry
insulating
mats
or covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and local
codes.
6. Turn oft all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
8.
Do
not
wrap
cables around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10. Do
not
touch
electrode
while
in
contact
with
the work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
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.
1.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shade of filter
(see
ANSI Z49.1
listed
in
Safety Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Wear
approved
safety
glasses.
Side
shields
recommended.
Use
protective
screens or
barriers
to
protect
others from flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made from
durable,
flame-resistant
material
(wool
and
leather)
and foot
protection.
Use
approved
ear
plugs
or ear
muffs
if
noise
level is
high.
1
2
\
A~
WARNING
2
a
CAUTION
/
1
Safety
Alert
Symbol
______________
3
I
~
ELECTRIC SHOCK
can
kill

MOVING
PARTS
can
Injure.
I

Do
not
touch live
electrical
parts.
h
1…~I.

Keep
away
tram
moving
parts.

Disconnect
input
power
before
installing
or
servicing.
J~j
~

Keep
all
panels
and
covers
closed
I
when
operating.
5
2
SignalWord
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
V
6
3
Statement Of
Hazard
And
Result
NOTE
~
READ
SAFETY
BLOCKS at
start
of
I
_____
Section
3-1 before
proceeding.
4
Safety
Instructions To Avoid
Hazard
Turn Off
switch when
using high frequency.
5
Hazard
Symbol
(If Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym.
bol
shown.
7
NOTE
Special
instructions for
best
oper
ation

not
related
to
safety.

FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes and
gases.
Breathing
these
fumes and
gases
can
be hazardous
to
your
health.
Keep
your
head
out
of the
fumes.
Do
not
breath the
fumes.
If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If ventilation is
poor,
use an
approved
air-supplied
respirator.
4.
Read the Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers instruction
for
metals, consumables,
coatings,
and cleaners.
5.
Work
in
a
confined
space
only
if
it is
well
ventilated,
or
while
wearing
an
air-supplied respirator.
Shielding
gases
used
for
welding
can
displace
air
causing injury
or
death. Be
sure
the
breathing
air is
safe.
6.
Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
operations.
The heat and
rays
of the
arc can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless the
coating
is removed from the
weld
area,
the
area
is well
ventilated,
and if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off toxic
fumes
if
welded.
Chipping
and
grinding
cause
flying
metal. As 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 FL
33126
Safetyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers That Have
Held
Hazardous
Substances,
American
Welding
Society
Standard AWS
F4.1,
from American
Welding
Society,
550
N.W.
LeJeune
Rd, Miami,
FL
33126
National Electrical
Code,
NFPA
Standard
70,
from
National Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety in Welding
and
Cutting,
CSA Standard
Wi
17.2,
from
Canadian Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale,
Ontario,
Canada M9W
1
R3.
Safe
Practices For
Occupation
And Educational
Eye
And Face
Protection,
ANSI Standard Z87.
1
,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
1.
2.
WELDING
can cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
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
of
electrode
orwelding
wire
6.
7.
Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can cause
fire
on
the hidden side.
.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
to
metal
objects
can
cause
sparks,
overheating,
or
fire,
8.
Connect work cable
to
the work
as
close
to
the
welding
area as
practical
to
prevent
welding
currentfrom
traveling long, possibly
.
1.
Protect
yourself
and others
from
flying sparks
and hot
metal.
2. Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
unknown
paths
and
causing
electric
shock and
fire
hazards.
Do
not
use
welder
to
thaw frozen
pipes.
3.
Remove all flammables within 35
ft
(10.7 m)
of
the
welding
arc.
If
this is
not
possible,
tightly
cover
them
with
approved
covers,
10. Remove stick electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
4.
Be alert that
welding sparks
and hot materials
from
welding
can
11.
Wearoil-free
protective
garments
such
as
leather
gloves, heavy
easily
go
through
small cracks and
openings
to
adjacent
areas,
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING SPARKS
AND
HOT
METAL
can
cause
injury,
1.
2.
Wear
approved
face shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body
protection
to
protect
skin.
CYLINDERS
can
explode
if
damaged.
3.
Keep cylinders
away
from
any
welding
or
other electrical
circuits.
1.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
4.
5.
6.
7.
Never allow
a
welding
electrode
to
touch
any
cylinder.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings designed
for the
specific application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from valve outlet when
opening cylinder
valve.
Keep protective
cap
in
place
over
valve
except
when
cylinder
is
in
use or
connected
for
use.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
8.
Read and follow instructions
on
compressed
gas
cylinders,
them
to
a
stationary
support
or
equipment cylinder
rack
to
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
prevent
falling
or
tipping.
Standards.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.

TABLE
OF
CONTENTS
SECTION
1

SPECIFICATIONS
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
1
SECTION 2INSTALLATION
2-1.
Installing
Work
Clamp
2
2-2.
Gun
Polarity
For
Wire
Type
2
2-3.
Installing
Welding
Gun
3
2-4.
Connecting
Input
Power
3
2-5.
Threading
And
Feeding
Welding
Wire
.
3
2-6.
Installing
Gas
Supply
5
SECTION
3OPERATION
6
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Overload
Protection
7
4-2.
Drive
Assembly
Maintenance
8
4-3.
Gun
Maintenance
9
4-4.
Troubleshooting
10
SECTION
5
ELECTRICAL
DIAGRAMS
11
SECTION
6
PARTS
LIST
Figure
6-1.
Main
Assembly
13
Figure
6-2.
Drive
Assembly,
Wire
15
Figure
6-3.
GA-i
6C1 Gun
16
OM.1
57 745
4/93