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Miller Electric GPS-500 Owner's Manual

Arc welding power source for use with a mog system
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www.MillerWelds.com
GPS-500, GPS-750
OM-266G
February 1993
Eff. w/Serial Number KB022118
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source For Use
With A MOG System

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Summary of Contents for Miller Electric GPS-500

  • Page 1 Eff. w/Serial Number KB022118 Processes TIG (GTAW) Welding Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source For Use With A MOG System GPS-500, GPS-750 Visit our website at www.MillerWelds.com...
  • Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......The following terms are used interchangeably 1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Specifications

    SECTION 2 – SPECIFICATIONS 2-1. Specifications Specification Description Type Of Output Direct Current/Constant Voltage (DC/CV) Welding Processes Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Core Arc (FCAW), Gas Tungsten Arc Welding (GTAW), Air Carbon Arc (CAC-A) Gouging, Stress Relieving, Resistance Heating Overall Dimensions See Section 3-3 Options...

  • Page 14: Duty Cycle

    2-3. Duty Cycle Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. This unit is rated at 100% duty cycle allowing continuous operation at rated load. Y Exceeding duty cycle can damage unit void warranty.

  • Page 15: Selecting A Location And Moving Welding Power Source

    3-2. Selecting A Location And Moving Welding Power Source 18 in (460 mm) Open Space On Front And Rear For Good Airflow Lifting Eye Use lifting eye to move unit. Lifting Forks Rear If using lifting forks, extend forks out opposite end of unit.

  • Page 16: Selecting And Preparing Weld Output Cables

    3-4. Selecting And Preparing Weld Output Cables Weld Output Cable Determine total cable length in weld circuit and maximum welding am- peres. Use Section 3-5 to select proper cable size. Use shortest cables possible. Do not use damaged cables. Terminal Lug Use lugs of proper amperage capacity and hole size for connect- ing to MOG terminal, and weld out-...

  • Page 17: Connecting To Weld Output Terminals

    3-6. Connecting To Weld Output Terminals NOTE This unit provides single polarity output to all MOG grids at the same time. Make weld cable connections for the welding polarity required – electrode positive (DCEP) or electrode negative (DCEN). Positive (+) Weld Output Ter- minal Negative (–) Weld Output Ter- minal...

  • Page 18: Positioning Jumper Links

    3-7. Positioning Jumper Links Jumper links allow operation on dif- ferent input voltages and are facto- ry set for the highest input voltage. Check input voltage available at site. Open rear access door to check jumper links. Input Voltage Label – Only One Is On Unit Look at jumper links and compare link position with unit label.

  • Page 19: Connecting Input Power

    3-8. Connecting Input Power Have only qualified persons make Tools Needed: this installation. Open rear access door. 1/2, 11/16 in Line Disconnect Switch Of Proper Rating Strain Relief Connector Obtain and install strain relief con- nector. Input Conductors Grounding Conductor Select size and length using Sec- tion 3-9 or Section 3-10.

  • Page 20: Electrical Service Requirements For 750 Ampere Models

    3-10. Electrical Service Requirements For 750 Ampere Models* Input Voltage Input Amperes At Rated Output Circuit Breaker Size In Amperes Fuse Size In Amperes Input Conductor Size In AWG/Kcmil Maximum Input Conductor Length In Feet (Meters) 187 (57) 270 (82) 421 (128) Grounding Conductor Size In AWG/Kcmil These values are calculated from the 1996 edition of the National Electrical Code (NEC).

  • Page 21: Work Clamp

    4-3. Work Clamp Work Clamp Tools Needed: Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. Connect work clamp to a clean, paint-free location on workpiece, as close to weld area as possible. sb4.1 5/92 4-4.

  • Page 22: Sequence Of Gas Metal Arc Welding (Gmaw)

    4-7. Sequence Of Gas Metal Arc Welding (GMAW) Install & Install & Install & Prepare Put On Turn On Connect Connect MOG Wire Feeding Personal Safety Set Controls Shielding Gas Equipment System System Equipment Turn On Feeder And Welding Begin Welding Power Source ssb6.1* 9/92 4-8.

  • Page 23: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Turn OFF all power before maintaining. 3 Months 6 Months Tape Or Blow Out Replace Cracked Vacuum Cables Inside During Heavy Service, Replace Clean Monthly Unreadable Labels Fan Motor Sealed Bearings – Clean No Oil Needed...
  • Page 24 B. Fuse F1 Turn OFF welding power source and disconnect input power. Fuse F1 protects the control circuit from overload. If F1 opens, the unit shuts down. Remove right side panel. Fuse F1 (see Parts List for size) Pull fuse from fuse holder. To rein- stall, push fuse into fuse holder.

  • Page 25: Troubleshooting

    5-3. Troubleshooting Trouble Remedy No weld output; unit completely inopera- Place line disconnect switch in the ON position (see Section 3-8). tive; pilot light PL1 not on. Check and replace open line fuse(s) (see Section 3-8). Check electrical input connections (see Sections 3-7 and 3-8). Press POWER CONTROL ON button (see Section 4-5).
  • Page 26 Notes OM-266 Page 22...

  • Page 27: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS SB-088 042-A Figure 6-1. Circuit Diagram For 500 Ampere Model SB-088 040-A Figure 6-2. Circuit Diagram For 750 Ampere Model OM-266 Page 23...

  • Page 28: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. Fig 7-3 & 7-4 Fig 7-2 ST-160 772 Figure 7-1. Main Assembly (500 Model Illustrated) OM-266 Page 24...
  • Page 29 Replace Coils At Factory Or Factory Authorized Service Station Quantity Model Item Dia. Part Description Mkgs. Figure 7-1. Main Assembly ....053 931 COVER, top ..........
  • Page 30 Quantity Model Item Dia. Part Description Mkgs. Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 19) ... 025 638 METER, volt dc 0-100 scale ........
  • Page 31 Item Part Description Quantity Figure 7-3. Terminal Assembly, Pri (Fig 7-1 Item 12) 035 398 038 126 ....601 835 NUT, brs hex 10-32 ......... .
  • Page 32 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-266 Page 28...
  • Page 33 Notes OM-266 Page 29...
  • Page 35 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...

  • Page 36: Options And Accessories

    FAX: 44 (0) 1204-598066 www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00...

This manual is also suitable for:

Gps-750

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