Introduction
This document provides technical information compiled to assist in troubleshooting the Miller Gold Star 140 and Gold Seal 160i welding machines.
Specifications
Gold Star 140
| Specification | Value |
|---|---|
| Input Voltage | 240v |
| Phase | 1 |
| Frequency | 50 Hz |
| Min recommended generator capacity | 6KVA |
| Power factor | 0.8 (140A) |
| Primary Fuse | 20 A (slow blow) |
| Open Circuit Voltage | 55v |
| Rated Current | 130A @ 60% 120A @ 100% |
| Dimensions | 310x135x235 mm |
| Weight | 6.5kg |
Gold Seal 160i
| Specification | Value |
|---|---|
| Input Voltage | 240v |
| Phase | 1 |
| Frequency | 50 Hz |
| Min recommended generator capacity | 6KVA |
| Power factor | 0.8 (150A) |
| Primary Fuse | 32 A (slow blow) |
| Open Circuit Voltage | 90A |
| Rated Current | 160A @ 60% 130A @ 100% |
| Pulsing Frequency | 0.5 - 300 Hz |
| Pre – flow of shielding gas | 0.5 sec |
| Post flow of shielding gas | 3 – 20 sec |
| Dimensions | 400x200x286 mm |
| Weight | 13kg |
Troubleshooting Approach
The troubleshooting sections utilize flowcharts to guide users through diagnosing issues. The process typically begins with a visual inspection for damage (e.g., burnt or swollen parts). If no visible faults are found, the machine is powered on, and subsequent steps involve checking for specific problems such as fan operation, voltage output, or LED indicators. Diagnostic paths often lead to checking voltage at various points (e.g., fan terminals, input switch, main filter, main voltage cable) or testing specific components like potentiometers, switches, or PCBs. The guides recommend replacing faulty components based on these checks. For example, if the fan does not work, voltage is checked at its terminals; if voltage is present, the fan is replaced; if not, the switch is checked. If the machine delivers no voltage, checks proceed from PCB terminals to input filters and cables, indicating potential faults on the plug or board if voltage is absent at the final check point.
Parts Lists
Gold Star 140 Parts List
| Item | Part Number | Description | Qty |
|---|---|---|---|
| 1 | 156 002 025 | Handle | 1 |
| 2 | 156 121 006 | Outer Case | 1 |
| 3 | 156 006 011 | Chassis | 1 |
| 4 | 057 101 005 | PC3, Filter PCB | 1 |
| 5 | 056 126 062 | Fan | 1 |
| 6 | 656 089 027 | Grommet | 1 |
| 7 | 057 014 096 | Primary Cable | 1 |
| 8 | 956 142 266 | Front Panel | 1 |
| 9 | 056 067 157 | On/Off Switch | 1 |
| 10 | 000 097 922 | Knob | 1 |
| 11 | 056 059 254 | Potentiometer | 1 |
| 12 | 116 170 002 | Grille | 1 |
| 13 | 057 098 009 | Inductor | 1 |
| 14 | 056 076 207 | Terminal | 1 |
| 15 | 056 159 010 | Thermostat | 1 |
| 16 | 058 075 002 | PC1 & PC2, Main & Logic PCB | 1 |
| 17 | 056 159 011 | Thermostat | 1 |
Gold Seal 160i Parts List
| Item | Code | Dwg | Qty | Diagram Ref. |
|---|---|---|---|---|
| 1 | 156002025 | UR.0.0.13 | 1 | |
| 2 | 156011021 | VG.0.0.11 | 1 | |
| 3 | 156121007 | VG.0.0.12 | 1 | |
| 4 | 057084088 | VG.0.10 | 1 | Logic P.C.B.6 |
| 5 | 057084074 | VG.0.4 | 1 | Controls P.C.B.5 |
| 6 | 356029201 | VG.0.0.13 | 1 | |
| 7 | 056067213 | VG.0.0.27 | 2 | S2-S3 |
| 8 | 056020046 | VG.0.0.14 | 1 | |
| 9 | 056020047 | VG.0.0.15 | 5 | |
| 10 | 156118021 | VG.0.0.16 | 1 | |
| 11 | 057098003 | UR.1.4 | 1 | XL |
| 12 | 756005018 | VG.0.0.17 | 1 | |
| 13 | 956142309 | VG.0.0.18 | 1 | |
| 14 | 056076209 | VG.0.0.19 | 2 | |
| 15 | 556049361 | VG.0.0.20 | 1 | |
| 16 | 056076170 | FS.1.0.3 | 1 | RC1 |
| 17 | 156006012 | VG.0.0.21 | 1 | |
| 18 | 057084075 | VG.0.5 | 1 | Sec. P.C.B.3 (V. 230) |
| 18 | 057084078 | VG.0.9 | 1 | Sec. P.C.B.3 (V. 240) |
| 19 | 057014097 | VG.0.6 | 1 | |
| 20 | 056159012 | VG.0.0.22 | 1 | TP. 80C |
| 21 | 056126062 | UR.0.0.7 | 1 | FM |
| 22 | 656089028 | VG.0.0.23 | 1 | |
| 23 | 116170002 | UR.0.0.17 | 1 | |
| 24 | 057101005 | VG.1.8 | 1 | Filter P.C.B.1 |
| 25 | 056020048 | VG.0.0.24 | 1 | S1 |
| 26 | 056067212 | VG.0.0.25 | 1 | TP 60C |
| 27 | 056159011 | UR.0.0.15 | 1 | |
| 28 | 057084076 | VG.0.7 | 1 | Main P.C.B.2 (V. 230) |
| 28 | 057084077 | VG.0.8 | 1 | Main P.C.B.2 (V. 240) |
| 29 | 058021115 | VG.6 | 1 | T2 (V. 230) |
| 29 | 058021116 | VG.7 | 1 | T2 (V. 240) |
| 30 | 056061045 | VG.0.0.26 | 1 | GS |
| 31 | 058021101 | VG.4 | 1 | T1 |
| 32 | 057084072 | OP.0.3 | 1 | HF. P.C.B.4 |
Diagrams
Gold Star 140 Circuit Diagram
This diagram illustrates the electrical connections and components for the Gold Star 140, including main PCBs, line filter, and electrode connections.
Gold Seal 160i Main Assembly Diagram
This diagram shows the exploded view of the Gold Seal 160i main assembly, detailing the placement of major components such as the outer case, chassis, fan, and PCBs.
Gold Seal 160i Circuit Diagram
This diagram details the electrical schematic for the Gold Seal 160i, showing connections between various PCBs, transformers, input power, and output terminals.
Contact & Disclaimer
Hugh Stewart, Technical Service Co-ordinator – Marketing
QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES
The information provided in this sheet is accurate and reliable; however, no warranty of accuracy or reliability is given, and no responsibility arising in any other way by errors or omissions is accepted.
