Miller GPS-1500V Owner's manual

Brand: Miller

Model: GPS-1500V

Category: Welding System

Type: Owner's manual

GPS-500, GPS-750

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

TIG (GTAW) Welding

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source For Use

With A MOG System

OM-266G February 1993

Eff. w/Serial Number KB022118

Visit our website at

www.MillerWelds.com

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. To locate your nearest

distributor or service agency call 1-800-4-A-Miller,

or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know

you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller products

had to be more than the best they could be. They had to

be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

The following terms are

used interchangeably

throughout this manual:

TIG = GTAW

Stick = SMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Volt-Ampere Curve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Duty Cycle 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Typical Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Selecting A Location And Moving Welding Power Source 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Overall Dimensions And Base Mounting Hole Layout 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Selecting And Preparing Weld Output Cables 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Cable Size* 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting To Weld Output Terminals 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Positioning Jumper Links 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting Input Power 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Electrical Service Requirements For 500 Ampere Models* 15. . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Electrical Service Requirements For 750 Ampere Models* 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Safety Equipment 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Work Clamp 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Ammeter And Voltmeter 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Power Control Push Buttons And Pilot Light 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Sequence Of Shielded Metal Arc Welding (SMAW) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Sequence Of Gas Metal Arc Welding (GMAW) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Sequence Of Flux Cored Arc Welding (FCAW) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Sequence Of Gas Tungsten Arc Welding (GTAW) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A) 18. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

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OM-266 Page 1

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.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-4. Read and follow all

Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

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.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D 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.

OM-266 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

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.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-266 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting 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 Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

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.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-266 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-266 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci–dessus.

OM-266 Page 9

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 See Rear Cover

500 Amp 750 Amp

Rated Weld Output 500 Amperes, 76 Volts DC At 100% Duty Cycle 750 Amperes, 76 Volts DC At 100% Duty Cycle

Type Of Input Power Three-Phase; 230, 460, Or 575 Volts AC; 60 Hz Three-Phase; 230, 460, Or 575 Volts AC; 60 Hz

Input Amperes At Rated Output 106 A At 230 V, 53 A At 460 V, 43 A At 575 V 164 A At 230 V, 82 A At 460 V, 66 A At 575 V

KVA/KW Used At Rated Output 42.8 kVA/41.7 kW 65.3 kVA/61.5 kW

Max. Open-Circuit Voltage 85 Volts DC 85 Volts DC

Weight Net: 480 lbs (218 kg); Ship 500 lbs (227 kg) Net: 660 lbs (299 kg); Ship 680 lbs (308 kg)

2-2. Volt-Ampere Curve

ssb1.1* 10/91 – Ref. SB-047 997-A

The volt-ampere curve shows the

voltage and amperage output capa-

bilities of the welding power source.

(750 Amperes Model)

(500 Amperes Model)

OM-266 Page 10

2-3. Duty Cycle

sb1.1 2/92 – Ref. SB-079 809-A

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 and void

warranty.

SECTION 3 – INSTALLATION

3-1. Typical Connections

(10) MOG Units

Welding

Power

Source

Common Work Circuit

OM-266 Page 11

3-2. Selecting A Location And Moving Welding Power Source

ST-158 380-A

1 18 in (460 mm) Open Space

On Front And Rear For Good

Airflow

2 Lifting Eye

Use lifting eye to move unit.

3 Lifting Forks

If using lifting forks, extend forks out

opposite end of unit.

4 Rating Label

Locate unit near correct input pow-

er supply.

Front

Rear

3-3. Overall Dimensions And Base Mounting Hole Layout

ST-158 377-A

Inches Millimeters

A 34 864

B 22-1/4 565

C* 32 813

D+ 1-3/4 44

E♦ 28-3/4 730

F 1-1/8 29

G 20 508

H 7/16 11

Front

*40 in (1016 mm) On 750 Amp Models

+1-1/2 in (38 mm) On 750 Amp Models

♦37 in (940 mm) On 750 Amp Models

OM-266 Page 12

3-4. Selecting And Preparing Weld Output Cables

10 ft (3 m)

sb6.1* 8/92 – Ref. S-0653

1 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.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to MOG terminal, and weld out-

put terminals and work connection.

Tools Needed:

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

3-5. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0

1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

1500 2-4/0 3-3/0 3-4/0 4-4/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. S-0007-C

OM-266 Page 13

3-6. Connecting To Weld Output Terminals

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).

NOTE

ST-158 378

1 Positive (+) Weld Output Ter-

minal

2 Negative (–) Weld Output Ter-

minal

For Electrode Positive (DCEP),

connect end of one cable to POSI-

TIVE (+) terminal, and remaining

end to MOG input terminal.

Connect end of other cable to NEG-

ATIVE (–) output terminal, and re-

maining end to work circuit.

For Electrode Negative (DCEN),

reverse cable connections.

Close door.

Tools Needed:

15/16 in

POSITIVE NEGATIVE

OM-266 Page 14

3-7. Positioning Jumper Links

ssb5.1* 2/92 – Ref. ST-158 381

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.

1 Input Voltage Label – Only

One Is On Unit

Look at jumper links and compare

link position with unit label.

2 Input Voltage Jumper Links

Move links to match input voltage.

For example, use 230 volts position

when 230 volts input power is avail-

able.

Close and secure rear access door

or go on to Section 3-8.

Tools Needed:

230 VOLTS

S-012 242-A

L1 L2 L3

460 VOLTS

L1 L2 L3

575 VOLTS

L1 L2 L3

230 VOLTS

S-020 426-A

L1 L2 L3

460 VOLTS

L1 L2 L3

3/8, 1/2 in

S-0092-E

OM-266 Page 15

3-8. Connecting Input Power

Have only qualified persons make

this installation.

Open rear access door.

1 Line Disconnect Switch Of

Proper Rating

2 Strain Relief Connector

Obtain and install strain relief con-

nector.

3 Input Conductors

4 Grounding Conductor

Select size and length using Sec-

tion 3-9 or Section 3-10. Conductor

rating must comply with national,

state, and local electrical codes.

Use lugs of proper amperage ca-

pacity and correct hole size.

5 Input Terminal Board

6 Line Terminals

7 Ground Terminal

Insert conductors through strain

relief.

Connect input conductors to line

terminals and grounding conductor

to ground terminal.

Install and connect input conduc-

tors and grounding conductor in

conduit or equivalent to deener-

gized line disconnect device.

Be sure grounding conductor goes

to an earth ground.

Close rear access door.

8 Overcurrent Protection

Select type and size using Section

3-9 or Section 3-10. Install into

deenergized line disconnect device

(fused disconnect switch shown).

ssb2.4* 2/93 – ST-158 381

47 3

Tools Needed:

1/2, 11/16 in

3-9. Electrical Service Requirements For 500 Ampere Models*

Input Voltage

230 460 575

Input Amperes At Rated Output

106 53 43

Circuit Breaker Size In Amperes

150 80 60

Fuse Size In Amperes

150 80 60

Input Conductor Size In AWG/Kcmil

2 6 8

Maximum Input Conductor Length In Feet (Meters)

155 (47) 261 (80) 259 (79)

Grounding Conductor Size In AWG/Kcmil

6 8 10

These values are calculated from the 1996 edition of the National Electrical Code (NEC).

1 Standard fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source (Article 630-12(a) of NEC).

2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway

(Table 310-16 of NEC).

3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles

210-19(a) and 215-2(b) of NEC).

4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be larger

than input conductor (Article 250-95 of NEC).

S-0092-E

OM-266 Page 16

3-10. Electrical Service Requirements For 750 Ampere Models*

Input Voltage

230 460 575

Input Amperes At Rated Output

164 82 66

Circuit Breaker Size In Amperes

250 125 100

Fuse Size In Amperes

250 125 100

Input Conductor Size In AWG/Kcmil

2/0 4 4

Maximum Input Conductor Length In Feet (Meters)

187 (57) 270 (82) 421 (128)

Grounding Conductor Size In AWG/Kcmil

4 6 8

These values are calculated from the 1996 edition of the National Electrical Code (NEC).

1 Standard fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source (Article 630-12(a) of NEC).

2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway

(Table 310-16 of NEC).

3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles

210-19(a) and 215-2(b) of NEC).

4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be larger

than input conductor (Article 250-95 of NEC).

SECTION 4 – OPERATION

4-1. Controls

Ref. ST-158 378

1 Voltmeter

2 Ammeter

3 Pilot Light

4 Circuit Breaker (See Section

5-2)

5 Power Control Push Buttons

1 2

4-2. Safety Equipment

1 Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet

Wear dry insulating gloves, safety

glasses with side shields, and a

welding helmet with a correct shade

of filter (see ANSI Z49.1).

sb3.1 10/91

123

OM-266 Page 17

4-3. Work Clamp

1 Work Clamp

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

Tools Needed:

4-4. Ammeter And Voltmeter

Ref. ST-059 546-G

1 Voltmeter

Voltmeter displays voltage at the

weld output terminals, but not nec-

essarily the welding arc due to

cable resistance, poor connec-

tions, etc.

2 Ammeter

Ammeter displays weld amperage

output of unit.

1 2

4-5. Power Control Push Buttons And Pilot Light

1 Pilot Light

2 Power Control Push Buttons

Use buttons to turn unit, pilot light,

and fan motor ON and OFF.

4-6. Sequence Of Shielded Metal Arc Welding (SMAW)

ssb7.1* 9/92

Install &

Connect

Equipment

Select

Electrode

Put On

Personal Safety

Equipment

Set Controls

Insert

Electrode

Into Holder

Turn On

Welding Power

Source

Begin Welding

Install &

Connect MOG

System

OM-266 Page 18

4-7. Sequence Of Gas Metal Arc Welding (GMAW)

Begin Welding

ssb6.1* 9/92

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Put On

Personal Safety

Equipment

Set Controls

Turn On

Shielding Gas

Turn On Feeder

And Welding

Power Source

Install &

Connect MOG

System

4-8. Sequence Of Flux Cored Arc Welding (FCAW)

Install &

Connect

Equipment

Install &

Connect

MOG System

Put On

Personal Safety

Equipment

Set Controls

Begin Welding

Install & Prepare

Wire Feeding

System

Turn On Feeder

And Welding

Power Source

4-9. Sequence Of Gas Tungsten Arc Welding (GTAW)

Turn On

Shielding Gas

ssb8.1* 9/92

Install &

Connect

Equipment

Install & Connect

High-Frequency

Unit

Select

Tungsten

Insert

Tungsten

Into Torch

Put On

Personal Safety

Equipment

Set Controls

Turn On

High-Frequency

Unit

Turn On

Welding Power

Source

Begin Welding

Install &

Connect MOG

System

4-10. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A)

Insert

Electrode

Into Torch

ssb8.1* 9/92

Install &

Connect

Equipment

Install & Connect

MOG System

Select

Carbon

Electrode

Put On

Personal Safety

Equipment

Set Controls

Turn On

Compressed

Air Supply

Turn On

Welding Power

Source

Begin

Cutting Or

Gouging

Connect

Compressed

Air Supply

OM-266 Page 19

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

Turn OFF all power before maintaining.

ST-158 379

3 Months

Blow Out

Vacuum

Inside

Clean

And

Tighten

Weld

Terminals

Replace

Unreadable

Labels

6 Months

Tape Or

Replace

Cracked

Cables

During Heavy Service,

Clean Monthly

Fan Motor

Sealed

Bearings –

No Oil

Needed

5-2. Overload Protection

A. Circuit Breaker CB

1 Circuit Breaker

Circuit breaker CB, labeled OVER-

LOAD, protects the welding power

source output circuit from overload.

If CB opens, weld output from the

welding power source stops. Re-

duce welding load, and reset break-

er.

Ref. ST-059 546-G

OM-266 Page 20

B. Fuse F1

ST-160 758 / ST-158 382-A

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.

1 Fuse F1 (see Parts List for

size)

Pull fuse from fuse holder. To rein-

stall, push fuse into fuse holder.

Reinstall side panel.

Tools Needed:

3/8 in

500 Ampere Model

750 Ampere Model

C. Overheating

Thermostats TP1 protects the unit from damage due to overheating. If main transformer T1 gets too hot, TP1 opens

and weld output stops. Wait several minutes before trying to weld. This unit will not reenergize by means of the POW-

ER CONTROL ON push button until proper cooling has occurred and all thermostats are closed.

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Miller GPS-1500V Owner's manual

Brand: Miller

Model: GPS-1500V

Category: Welding System

Type: Owner's manual

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