Download Miller Electric GPS-1500 Specifications

August 1978
FORM: OM-267
Effective With Serial No. HJ165871
MODEL
GPS- 1000
GPS- 1500
OWNERS
IIlIIIER
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI
54912 USA
ADDITIONAL COPY PRICE 55 CENTS
NWSA CODE NO. 4579
PRINTED
IN U.S.A.
r
L
-~
L.
-
-
.
5
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 20, 1978
This warranty supersedes all previous MILLER warranties and is
clusive with
LIMITED WARRANTYMiller
no
other guarantees
or
warranties expressed
Electric Mfg. Co.. Apple.
new and unused
ton, Wisconsin warrants to Customer that all
furnished
Equipment
and
v~rkmanship
Miller
by
material
is
of
as
free
the
from
time
defect
Miller. No warranty is made by Miller with
engines, trade accessories or other items manufactured by others. Such engines, trade accessories and other
items are sold subject to the warranties of their respective
if
manufacturers,
is for
engines
The
any.
period of
a
one
MILLER warranty does
normal
useful
welder
tips,
parts that
life
relay
come
of
apply
than
one
warranty
Original
3.
All
4.
All other Millermatic Feeders
to
components
(1(
year, such
5.
of Millers
case
spot
MILLERMATIC
the
or
material.
ANY
breach of warranty
payment of
or
or,
at
OR
an
Customers
(3(
the
reasonable
authorized
Miller
upon actual
or
REMEDY
FOR
BUT
in
service
station
or
or
All
return
of the
transactions are
goods
FOB.
Upon receipt of notice of apparent
failure, Miller shall instruct the claimant on the
OR
IMPLIED
NOT
WARRANTY
PROVIDED
AS
PERFORMANCE, AND
CONTRACT WHICH,
TO
BREACH OF
MIGHT
PROVISION,
OPERATION
COURSE OF
WARRANTY OF
OF
LAW,
ARISE
CUSTOM
BY
OF
DEALING, INCLUDING ANY
MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT
ANY
TO
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND
AND
warranty claim procedures to be followed.
FOR OPERATION
EXPERIENCED
BY PERSONS TRAINED
IN THE USE AND MAINTENANCE
OF WELDING EOUIPMENT AND NOT, FOR CONSUMERS
As
a
matter
of
general policy only, Miller
may honor
an
warranted
Equipment
in
original users
warranty claims
the
failure
of
)
(41
or
Appleton, Wisconsin.
defect
1 year
IMPLIED WARRANTY, GUARANTY
FOR
THIS
any other
writing by Miller
of repair
cost
usel upon
risk and expense.
ANY
REPRESENTATION
ANY
credit for the purchase price (less reasonable
depreciation based
at
in
where authorized
cases,
90 days
repair parts exclusive of labor 60 days
or
EXPRESS
HEREIN AND
IMPLICATION,
duty with respect to the quality of any goods, the exclusive
remedies therefor shall be, at Millers option, (11 repair or (2(
replacement
appropriate
replacement
onlyl
1 year
welding guns and feeder/guns
Replacement
TRADE
the
3 years
provided that the user so notifies Miller in writing within thirty
(301 days of the date of such failure.
having
as
nozzles and nozzle insulators where failure does not result
In
1 year
.
main power rectifiers
(Labor
on
points,
welding wire including
contactor
in contact with
from defect in workmanship
Arc welders, power sources, and componenss.
year.
not
less
and
manufacturers
1.
2.
in
to
respect
ex
implied.
place of
and
by
delivery
or
on
from
defect
within
OR
the
a
event
resulting
following periods from the date of delivery of Equipment
the original user:
to
CONSUMER
USE.
MILLER
WARRANTIES
EXTEND TO, AND NO RESELLER
EXTEND
MILLERS
DO
WARRANTIES
TO,
CONSUMER.
~b
NOT
IS AUTHORIZED TO
..~t,
d~
ANY
)
ERRATA SHEET
After this manual
was
printed, refinements in equipment design occurred. This sheet lists exceptions
to data
appearing later in
this manual.
AMENDMENT TO SECTION 3
INSTALLATION
Amend Section 3-3C. WELD OUTPUT CONNECTIONS
When the weld output terminals are not bused together, 500 amperes of weld output is available between one ,.~ Positive and
A Negative output terminals of the 1000 ampere models. Simultaneously, 500 amperes of weld output is available between
B Positive and B Negative output terminals of the 1000 ampere models. 750 amperes of weld output is available from the
1500 ampere models when similiar connections are made. When the weld output terminals are bused together, 1000 amperes
of weld output is available between the A Positive and A Negative or B Positive and B Negative output terminals of the 1000
amperes models. 1500 amperes of weld output is available from the 1500 ampere models when similiar connections are made.
one
These units
are
shipped with the bus bar in place.
CAUTION
If the positive output terminal of one section of this power source is connected to the negative output
terminal of the other section, two times the normal output voltage will exist between the remaining two
1output terminals.
Consult applicable safety codes.
AMENDMENT TO SECTION 6
TROUBLESHOOTING
NOTE
circuit
diagram(s)
on
this errata sheet
replaces
any other circuit
diagram(s)
1
for 1000 ampere models
1appearing later in this manual.
Amend
Figure 6-1. Circuit Diagram
Circuit
Diagram No.
B-080 675
Figure 6-1. Circuit Diagram For 1000 Ampere Models
OM-267 Page A
TABLE OF CONTENTS
Page
Section No.
SECTION 1
1
1
-
-
1.
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
Introduction
2. General Precautions
1-3.
Arc
1
Standards Booklet Index
-
4.
SECTION 2
No.
Welding
1
1
3
4
INTRODUCTION
2-1. General
5
2- 2.
Receiving-Handling
5
2- 3.
Description
5
2-4. Safety
SECTION 3
5
INSTALLATION
3-1.
Location
6
3- 2.
Electrical Input Connections
6
3. 3. Weld Output Connections
SECTION 4
4
4
-
-
8
OPERATION
1.
Power Control, Switch
8
2.
Overload Protection
9
4-3. PilotLight
4-4. Meters
9
4
9
-
5.
SECTION 5
Duty Cycle
9
MAINTENANCE
5-1.
FanMotor
9
5- 2.
Internal Cleaning
9
5
-
3. Control Circuit Protection
SECTION 6
TROUBLESHOOTING
9
1-SAFETY RULES FOR OPERATION OF ARC
SECTION
1-1.
harmful
INTRODUCTION
POWER SOURCE
WELDING
of
concentrations
toxic
exhaust ventilation mutt be used,
as well as the operator myst wear
learn by experience. Learning safety through personal
experience, like a child souching a hot stove is harmful,
wasteful, and unwise. Let she experience of others teach you.
We
For beryllium, both
or
fumes. Adequate local
each person in the area
air-supplied respirator.
an
mutt be used.
or containing materials that emit toxic
fumes should not be heated unless coating is removed from
the work surface, the area is well ventilated, or the operator
Metals coated with
Safe practices developed from experience in the use of weld
ing and cutting are described in this manual. Research, devel.
opment, and field experience have evolved reliable equipment
air-supplied respirator.
wears an
installation, operation, and servicing practices. Acci
dents occur when equipment is improperly used or main
tained. The mason for the safe practices may not always be
given. Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the rules.
and safe
Work
and,
in
confined space only while it is being ventilated
a
if necessary, while
Gas leaks in
a
wearing
an
air-supplied respirator.
confined space should be avoided. Leaked gas
large quantities can change oxygen concentration danger
ously. Do not bring gas cylinders into a confined space.
in
Read and understand
these safe practices before attempting
install, operate, or service the equipment Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
to
Failure
jury
can
observe these safe
to
practices
death. When safety becomes
be used with confidence.
or
a
Leaving confined space, shut OFF gas supply at source to
possible accumulation of gates in the space if down
stream valves have been
accidently opened or left open.
Check to be sure that the space is safe before re-entering it.
Prevent
may cause serious in
Vapors from chlorinated solvents can be decomposed by the
heat of the arc (or flame( to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultra
violet (radiant( energy of the arc can alto decompose tn
habit, the equipment
safe practices are divided into two Sections: 1
General Precautions, common to arc welding and cutting; and
2 Arc Welding (and Cutting((only(.
These
-
chloroethylene and perchloroethylene
gene.
DO
NOT WELD
Reference standards: Published Standards on safety are also
available for additional and more complete procedures than
those given in this manual. They are listed in the Standards
Index in this manual. ANSI Z49.1 is the most complete.
Electrical Code, Occupational Safety and
Administration, local industrial codes, and local in
spection requirements also provide a basis for equipment in
stallation, use, and service.
The
National
Health
drawn
into the welding
vapors to form phot
where solvent vapors can be
cutting atmosphere or where the
cut
or
-
or
radiant energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or perchioroethylene.
C.
Fire and
Explosion Prevention
Causes of fire and explosion are: combustibles reached by the
arc, flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and short circuits.
AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the goggled
operator. Sparks and slag can fly 35 feet.
BE
1 -2.
A.
GENERAL PRECAUTIONS
Burn Prevention
leather (or asbestos( gauntlet
protective clothing
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear
-
To prevent fires and explosion:
Keep equipment clean and operable, free of oil,
(in electrical parts( of metallic particles that can
grease, and
short
cause
circuits.
glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear caier glass(. This is a MUST for welding or cutting, (and
chipping( to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
Wear helmet with safety
goggles
or
See 1-3A,2,
If combustibles
are
in
area, do
NOT weld
or cut.
Move the
if
practicable, to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage areas, ventilators. If the
work cannot be moved, move combustibles at least 35 feet
away out of reach of sparks and heat; or protect against
work
ignition with suitable
and
snug-fitting, fire-resistant
covert or
shields.
Avoid
Hot
oily
or
metal
never
clothing.
greasy
such
A
spark
electrode stubs
be handled without gloves.
ignite them.
workpieces
and
as
Medical first aid and eye
may
should
First aid facilities and
treatment.
a
person should be available for each shift
unless medical facilities are close by for immediate treatment
qualified first aid
Walls touching combustibles on opposite sides should not be
welded on (or cut(. Walls, ceilings, and floor near work
should be protected by heat-resistant covers or shields.
Fire watcher mutt be standing by
tinguishing equipment during and for
ing or cutting if:
with
some
suitable fire ex
time after weld
of flash burns of the eyes and skin burns.
a.
Ear
plugs
should be
worn
when
working
overhead or in a
when others work
confined space. A hard hat should be
ove the ad.
worn
Flammable hair preparations should
intending to weld or cut.
not
b.
c.
B.
be used by persons
d.
Toxic Fume Prevention
appreciable
combustibles (including building construc
within 35 feet
appreciable combustibles are further than 35 feet but can
be ignited by sparks
tion(
on
openings (concealed or visible( in floors or walls within 35
feet may expose combustibles to sparks
combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
Hot work permit should
ensure
Adequate ventilation. Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding (or cutting( may produce. Prevent
them with adequate ventilation as described in ANSI Stan
dard Z49.1 listed
with oxygen.
Lead
and
-,
cadmium
similar
-,
1
Standards
in
are
index. NEVER ventilate
supervisors
be obtained before operation to
approval that adequate precautions have
been taken.
After work it done, check that
embers, and flames.
area
is free of sparks,
An empty container that held combustibles, or that
duce flammable or toxic vapors when heated, must
zinc
materials,
mercury -, and
when welded (or
-,
beryllium bearing
cut( may produce
-
glowing
can pro
be
welded on or cut, unless container has first been cleaned as
described in AWS Standard A6.O, listed 3 in Standards index.
never
OM-267 Page 1
steam or caustic cleaning (or a
washing, depending on the combustibles
solubility) followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom
mended in A6.0. Waterfilling just below working level may
substitute for inerting.
This
includes:
solvent
thorough
a
water
or
unknown contents should be cleaned (see
A container with
paragraph above).
to
Do NOT depend on
determine if it is safe to weld or cut.
Hollow
or
or
can
castings
cutting. They
sense
of smell
or
Protect cylinders particularly valves from bumps, falls,
objects, and weather.
cylinders.
Replace
Stuck
use
a
not
be opened by hand.
Do NOT
valve.
cylinder valve that
supplier.
Never try to
welding
wrench to open
Notify
a
your
mix~any gases
in
a
cylinder.
Never refill any cylinder.
Cylinder fittings should
weld
or
or cut
liquid
never
be modified
or
exchanged.
where the air may
vapors
(such
as
gaso
3.
Hose
-
Prohibited
D.
or
falling
moving
explode.
Explosive atmospheres. Never
Contain flammable dust, gas,
line)
hammer
when
sight
Mixing gases.
containers must be vented before
can
securely
caps
Compressed
Gas
Equipment
use.
the
specified
Use
ferrules
Never
use
hose other than that
designed for
gas. A general hose identification wle is: red for
fuel gas, green for oxygen, and black for inert gases.
Standard
precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, PRECAU
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
1.
Pressure
wire
or
clamps designed for the hose (not ordinary
as a binding to connect hoses to
fittings.
No cop~5er
Regulators
or
other substitute)
Use only standard brass
tubing splices.
fittings
to
splice hose.
Regulator
relief valve is designed to protect only the regula
overpressure; it is not intended to protect any
downstream equipment. Provide such protection with one or
from
tor
relief devices.
more
Avoid long runs
ground to keep
wise damaged.
Never connect a regulator to a cylinder containing gas other
than that for which the regulator was designed.
Coil
Remove faulty regulator from service immediately for repair
(first close cylinder valve). The following symptoms indicate
slag, and
excess
if gas leaks externally.
Leaks
if delivery pressure continues
Excessive Creep
downstream valve closed.
-
if
Faulty Gauge
when pressurized,
-
gauge
nor
pointer does
tangles.
damage by sharp edges, and by sparks,
returns
to
stop
pin
Clean
Cylinders
be
handled
walls, valves,
hose regularly for leaks, wear, and loose connec
Immerse pressured hose in water; bubbles indicate
carefully to prevent
safety devices:
leaks and
or
hose by
worn
(1-2D3). Do NOT
Repair. Do NOT attempt repair. Send faulty regulators for
repair to manufacturers
designated repair center, where
special techniques and tools are used by trained personnel.
must
from
Suspend hose off
stepped on, or other
open flame.
Repair leaky
off stop pin
after pressure
not move
4.
to their
over,
rise with
to
release.
Cylinders
run
leaks.
-
damage
being
Examine
faulty regulator:
tions.
2.
prevent kinks and abuse.
it from
hose to prevent kinks and
Protect hose
a
to
use
cutting
area out
and
splicing
tape.
Proper Connections
cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lintless cloth.
Match
regulator to cylinder. Before connecting, check that
regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet match. NEVER CON
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
the
or
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit arcs that may lead to a serious accident. (See
1-3C.)
Tighten connections. When assembling threaded connections,
ICC
or
DOT
assurance
marking must be on each cylinder. It is
of safety when the cylinder is properly handled.
Identifying
marked
an
gas content. Use only cylinders with name of gas
them; do not rely on color to identify gas con
on
Notify supplier
tent.
name,
number,
or
if unmarked. NEVER DEFACE or alter
other markings on a cylinder. It is illegal
and hazardous.
Empties: Keep valves closed, replace caps securely;mark MT;
keep them separate from FULLS and return promptly.
Prohibited use. Never use a cylinder or its
than its intended use, NEVER as a support
Locate
or
secure
Passageways
where
they
and
cylinders
work
so
areas.
they
contents
or
cannot be
clean and smooth seats where necessary. Tighten, If connec
tion leaks, disassemble, clean, and retighten using properly
fitting wrench.
Adapters. Use
a CGA
between cylinder and
wrenches to tighten
HAND threads.
adapter (available from your supplier)
regulator, if one is required. Use two
adapter marked RIGHT and LEFT
Regulator outlet (Or hose) connections may be identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
for other
5.
roller.
knocked
over.
Keep cylinders clear of
areas
may be struck.
Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder (or manifold valve) by turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at high pressure seat by allowing seat to open on pressur
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Transporting cylinders.
such
as
a
ground by
platfon-n
or
their valves
With a crane, use a secure support
cradle. Do NOT lift cylinders off the
or
caps,
or
by chains, Slings,
or
Stand to side of
regulator
while
opening cylinder
valve.
mag
nets.
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge reaches regu
creases
Do NOT expose cylinders to excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed 130F.
Cool with water spray where such exposure
exists.
Page
2
lator maximum) leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
possible leak. For fuel gas, open to less than one turn to
permit quick emergency shutoff.
Use pressure charts (available from
and efficient, recommended pressure
your
supplier)
settings
on
operation with low-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
for safe
regulators.
level.
pressurization and regularly there
or
after. Brush with soap solution (capful of Ivory Liquid
equivalent per gallon of water(. Bubbles indicate leak. Clean
for leaks
Check
off soapy
first
on
Viewing the weld. Provide face shields for all persons who
looking directly at the weld.
will be
after test; dried soap is combustible.
water
Others working in
E.
User
Responsibilities
Remove leaky or defective equipment from service immed
iately for repair. See User Responsibility statement in equip
ment
F.
See that all persons
area.
are
wearing
flash
goggles.
starting
Before
doors
are
weld, make
to
sure
that
screen
flaps
or
bay
closed.
manual.
Leaving Equipment Unattended
B.
Toxic Fume Prevention
-
supply
Close gas
C.
and drain gas.
at source
Comply
Rope Staging-Support
in 1-2B.
be vented to the outside air.
muss
or cut
C.
Fire and
Explosion
ARC WELDING
Comply
Comply with precautions in 1-1, 1-2, and this section. Arc
Equipments
equipment. Is
is a safe process, but a careless opera
trouble, The equipment carries high currents at
significant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weld
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
creases
standards referenced in index.
to
Welding, properly done,
Prevention
in 1-2C.
precautions
with
rated
Do
capacity.
not
may overheat cables and
overload
cause a
welding
arc
fire.
invites
tor
A.
precautions
Generator engine exhaust
Carbon monoxide can kill.
Rope staging-support should not be used for welding
ting operation; rope may burn.
1-3.
with
Burn Protection
Comply
in 1-2.
WITH PRECAUTIONS.
Protective
such
an
arc
on
a
overheat
cylinder
that
a
brittle
a
rupture later under
area
or
flash and
cause
a
E.
can
or
cause
other pressure vessel, Is
violent rupture or lead
a
rciugh handling.
Compressed Gas Equipment
Comply wish precautions
The welding arc is intense and visibly bright Its radiation can
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
GET BURNED; COMPLY
more severe and painful. DONT
1.
Never strike
D.
precautions
with
Loose cable connections may
fire.
in 1-2D.
Shock Prevention
Exposed hot conductors
or
other bare metal in she
welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON. OR TOUCH a wet sur
face when welding, without suitable protection.
Clothing
To protect against shock:
Wear long-sleeve clothing (particularly for gas-shielded arc) in
addition to gloves, hat, and shoes (1-2A). As necessary, use
additional protective clothing such as leather jacket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated cotton.
Keep body and clothing dry. Never work in damp area with
out adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or moisture between body
and an electrically HOT part
reduces
or grounded metal
the body surface electrical resistance, enabling dangerous and
possibly lethal currents so flow through she body.
-
protection. Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre
vent entry of sparks.
Bare skin
Grounding
1.
the
-
Equipment
Eye and Head Protection
2.
installing, connect the frames of each unit such as
welding power source, control, worktable, and water circula
tor to the building ground. Conductors muss be adequate so
carry ground currents safely. Equipment made electrically
When
Piotect
tric
from exposure to
without protection.
arc
Welding
12
or
before
helmet
or
denser
must
striking
arc.
Protect filter
plate
NEVER look at
arc.
eyes
an
elec
shield containing a filter plate shade no.
be used when welding. Place over face
with
a
clear
cover
plate.
HOT by stray current may shock, possibly fatally. Do NOT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammable liquid such as oil or fuel.
Three-phase
ment
Cracked
radiation
broken helmet
or
can
pass
through
or
shield should
to cause
NOT be
worn;
burns.
Cracked, broken, or loose filter plates must be replaced IM
MEDIATELY. Replace clear cover plate when broken, pitted,
or
connection. Check phase requirement of equip
installing. If only 3-phase power is available,
single-phase equipment to only two wires of she
3-phase line. Do NOT connect the equipment ground lead so
the third (live) wire, or the equipment will become electri
a dangerous condition that can shock, possibly
cally HOT
fatally.
connect
-
spattered.
Before
Flash
goggles
helmet so
with
give
not be lowered
side
some
over
MUST
shields
protection
be
so the eyes
the face before
an arc
under the
worn
should the helmet
is struck. Looking
at an arc momentarily
unprotected eyes (particularly
high intensity gas-shielded arc) can cause a retinal burn that
with
may leave
3.
before
a
permanent dark
a
area
in the field of vision,
room
or
welding
area.
enclosed bay
For
production welding,
is best.
In
welding,theck ground for continuity. Be sure conduc
touching bare metal of equipment frames at connec
are
ti ons.
If
line cord with a ground lead is provided with she equip
for connection so a swischbox, connect the ground lead
to the grounded swischbox. If a three-prong plug is added for
a
ment
connection so a grounded
must be connected to the
Protection of Nearby Personnel
Enclosed
tors
a
separate
open areas, surround
the
mating receptacle, she ground lead
ground prong only. If the line cord
comes with a shree.prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug wish a broken off ground prong.
)
Trademark of Proctor & Gamble.
OM-267 Page 3
2.
Electrode Holders
Do
not
If,
in
open power circuit or change polarity while welding.
emergency, it must be disconnected, guard against
an
Fully insulated electrode holders should be used. Do NOT
holders with protruding screws.
shock burns,
3.
connect
or
flash from switch arcing.
use
Leaving equipment unattended. Always
all power to equipment.
Connectors
Fully insulated lock-type
welding cable lengths.
4.
connectors
should be used
to
Power disconnect switch
join
power
1-4.
Cables
Frequently
inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
lethal shock from
damaged insulation to avoid possibly
bared cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable.
must
shut OFF
be available
near
the
and dis
welding
source.
STANDARDS BOOKLET INDEX
For
more
information, refer to the following standards
comply as applicable:
or
their latest revisions and
-
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks.
1.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, Fla, 33125.
2.
ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA
TION AND EDUCATIONAL EYE AND FACE PROTEC
TION, obtainable from American National Standards
Institute. 1430 Broadway, New York, N.Y. 10018.
3.
A6.0, WELDING
CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
Terminals And Other Exposed Parts
5.
Terminals and other
have
insulating
covers
exposed parts of electrical units should
secured before operation.
American
AND
6.
Electrode Wire
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed. Keep hands and body clear of wire and
other HOT parts.
4.
51, OXYGEN-FUEL GAS SYSTEMS
AND CUTTING, obtainable from the
National Fire Protection Association, 470 AtlantIc
Avenue, Boston pMass. 02210.
7.
5.
NFPA Standard 51B, CUTTING AND WELDING PRO
CESSES, obtainable same as item 4.
interlocks and circuit breakers should
shunted out.
6.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turning ON of power. Discon
nect all cables from welding power source, and pull all 115
CGA Pamphlet P-i. SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N. V. 10036.
7.
OSHA Standard 29 CFR, Part 1910, Subpart
ING, CUTTING AND BRAZING.
Safety Devices
Safety
as
not
or
devices such
be disconnected
volts line-cord plugs.
Page
4
Welding Society Standard
CUTTING
NFPA Standard
FOR WELDING
0, WELD
SECTION 2- INTRODUCTION
Input At Rated
Model
100% Duty
Cycle
60 Hz. Three-Phase
Open-
Weight
Amperes At
Circuit
Voltage
Output
Load
Max.
Rated Welding
Current Amperes
230 Volts
(Pounds)
Dimensions
460 Volts
kva
kw
(Inches)
Net
Ship
896
986
1068
1158
Height-41-1/8
1000
1000@76 Volts
85
224
112
89
85
Width -27-1/4
Depth
-
46
Height-41-1/8
1500
1500@l6Volts
85
330
131
165
123
Width
-27-1/4
Depth -46
Figure 2-1. Specifications
TB-080 172
Figure
2-1.
2-2. Functional
This will help avoid possible injury
welding applications.
GENERAL
This manual has been prepared especially for use in familiar
izing personnel with the design, installation, operation, main
tenance, and troubleshooting of this equipment. All informa
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
2-2.
Diagram
due to misuse
or
improper
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
U
Under this
heading, installation, operating, and main
procedures or practices will be found that if
carefully followed may create a hazard to per
I
tenance
not
I
sonnel.
I
flTANT
I
I
Under
this
heading, installation, operating, and main
procedures or practices will be found that if
carefully followed may result in damage to equip
tenance
2.3.
DESCRIPTION
This
not
incorporates a three phase Delta
(CP) type main power
connected, constant potential
transformer to provide the constant voltage output required
to operate the resistance grid welding stations connected to
welding
power
source
U
ment.
I
L
the unit.
2-4.
SAFETY
Before the equipment is put into operation, the safety sec
tion at the front of this manual should be read dompletely.
Under
this
NOTE
I
heading, explanatory
statements
will
found that need special emphasis to obtain the
efficient operation of the equipment.
be
most
U
OM-267 Page 5
SECTION 3
-
INSTALLATION
3-2.
A.
ELECTRICAL INPUT CONNECTIONS
Electrical Input Requirements
This welding power source is designed to be operated from a
three-phase, 60 Hertz, ac power supply which has a line volt
the electrical input
age rating that corresponds with one of
voltages shown on the nameplate. Consult the local electric
utility if there is any question about the type of electrical
system available at the installation site or how proper connec
tions to the welding power source are to be made.
Input Conductor Connections
B.
NOTE
It
is
recommended
in
installed
that
a
line disconnect
input circuit
the
the
to
switch be
welding
power
and convenient
means to completely remove all electrical power from
the welding power source whenever it is necessary to
perform any internal function on the unit
source.
*Including 2-7/8
This
provide
would
safe
a
Lifting Eye
TB-07g 823
Figure 3-1. Overall Dimensions And Base Mounting
Hole Layout
3-1.
LOCATION
A
electr ical input conn ec tions to the
ma k ing
lockout
welding power source, machinery
procedures should be employed. If the connection is
to
(Figure 3-1)
be
line disconnect switch, the switch
in the open position. If the
a
padlocked
connection is made from a fuse box, remove the fuses
from the box and padlock the cover in the closed
position. If the unit is connected to a circuit breaker,
other disconnecting device without locking
or
facilities, attach a red tag to the device to warn others
proper installation site should be selected for the welding
source if the unit is to provide dependable service, and
power
remain
be made from
should
relatively maintenance free.
A
proper installation site permits freedom of air movement
into and out of the welding power source, and also least
subjects the unit to dust, dirt, moisture, and corrosive vapors.
A minimum of 18 inches of unrestricted space must be main
tained between the welding power source front and rear
that the circuit is
nearest obstruction. Also, the underside of the
power source must be kept completely free of
obstructions. The installation site should also permit easy
removal of the welding power source outer enclosure for
being worked
on.
panels and the
welding
Connect the input conductors to the welding power
before making connections to the three-phase
source
maintenance functions.
power
un:
The input conductort should be covered with an insulating
material which conforms to local electrical standards. Table
3-1 is provided only as a guide for selecting the proper size
input conductors and fuses.
thve r the in ta ke air
place any
passages of the welding power source as this would
restrict the volume of intake air and thereby subject
the welding power source internal components to an
overheating condition and subsequent failure. War
ranty is void if any type of
filtering
supply.
Table 3-1.
Input Conductor and Fuse Size
device is used
Holes are provided in the welding power
mounting purposes. Figure 3-1 gives overall
the base mounting hole layout.
base for
dimensions and
input Conductor SizeS AWO
Fuse Size In Amperes
source
Model
230 Voile
460 Volrs
575 Volts
230 Volts
460 Volts
1000 Ampere
4/0 (2)
2 )e)
4 (8)
350
175
125
1500 Ampere
400 MCM (1/0)
2/0 (4)
1/0 (6)
500
250
225
575 Volts
most welding power sources a lifting device is provided
moving the unit. However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under the base.
On
for
ulnput conductor sizes
are
based
on
allowable
ampacities of
insulated copper conductors, having a temperature rating of
75C, with not more than three conductors in a raceway or
cable.
The
use
of lift forks too short to extend out of the
internal com
the lift forks
opposite side of the base will expose
ponents to damage should the tips of
penetrate the bottom of the unit.
Page 6
Numbers in I I
are
equipment ground
conductor sizes.
I
Insert the three input conductors
the access hole on the
through
accept standard conduit
tion and size.
plus
rear
one
ground
conductor
panel. This hole will
fittings. See Figure 3-2 for hole loca
230 VOLTS
thatatermi nal
recommended
lug
of
be of proper size to accommodate
the line and ground terminal studs.
lug
o1~~0Io
0I~6I
adequate
amperage capacity be attached to the ends of the in.
put and qround conductors. The hole diameter in the
terminal
460 VOLTS
must
to
0j
10
01
O
10
0~
0
10
~I10
01
O
10
01
o
Connect the three input conductors to the line terminals on
the contactor. Connect the ground conductor to the terminal
labeled GROUND on the frame near the contactor. The
remaining end of the ground conductor should be connected
a
proper ground. Use a grounding method that is
acceptable to the local electrical inspection authority.
to
059 530
Figure 3-3. Input Voltage Jumper Link Arrangement
!
U The
ground
power
terminal
is
chassis
and
source
Do not connect
only.
connected
is
for
to
the
C.
welding
purposes
conductor from the ground
a
terminal to any one of the line terminals as this will
result in an electrically energized welding power
i
source
Matching The Welding Power Source To The Avail
Voltage
able Input
grounding
The input voltage Jumper links provided on the primary ter
minal board permit the welding power source to be operated
from various line voltages. The various voltages from which
this unit may be operated are stated on the nameplate and on
chassis.
input voltage label. The input voltage jumper links are
positioned for the highest of the voltages stated on the
nameplate. If the welding power source is to be operated
from a line voltage which is lower than the highest voltage for
which the unit was designed, the jumper links will have to be
moved to the proper positions before operating the unit.
Figure 3-3 shows the various positions of the jumper links on
the standard welding power source. If the input voltages on
the nameplate differ from those shown in Figure 3-3, the
input voltage jumper links must be positioned as shown on
the input voltage label.
the
NOTE
If only one jumper link is required on each of the
grouped terminals, it is recommended that the unused
umper links be placed across the terminals which are
to be used. This will prevent losing the Jumper links
which are not required for this connection.
TB-079 825
Figure
3-2.
Input Conductor Connections
Table 3.2.
Welding
Cable Size
Lengt h Of Cable ( Copper) In W eld Circuit
Total
Amperes, DC
Welding
200
250
300
350
400
100
4
4
2
2
2
1
1/0
150
2
2
2
1
1/0
2/0
1/0
3/0
200
1
1
1
1/0
2/0
3/0
4/0
2-2/0
4/0
2-2/0
2-3/0
50
100
150
250
1/0
1/0
1/0
2/0
3/0
4/0
300
2/0
2/0
2/0
3/0
4/0
2-2/0
350
3/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-3/0
400
3/0
3/0
3/0
3/0
2-2/0
2-3/0
2-4/0
500
4/0
4/0
4/0
4/0
2-2/0
2-3/0
2-4/0
600
4/0
4/0
2-2/0
2-3/0
700
4/0
2-3/0
2-4/0
500MCM
800
2-2/0
4/0
2-2/0
2-4/0
1000MCM
900
2-3/0
2-3/0
2-3/0
2-4/0
500MCM
1000
2-3/0
2-3/0
2-4/0
1000MCM
1250
2-4/0
2-4/0
2-4/0
500MCM
1000MCM
500MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000MCM
2-4/0
500MCM
1000MCM
1000MCM
1500
500MCM
500MCM
1000MCM
1000MCM
1000MCM
1750
1000MCM
I000MCM
1000MCM
1000MCM
2000
1000MCM
1000MCM
1000MCM
2-4/0
3/0
TA-052 764
NOTE:
A.
5OFEETORLESS.
8.
CABLE SIZE IS BASED ON DIRECT CURRENT (DC), 100% DUTY CYCLE AND EITHER A
4 VOLTS OR LESS DROP OR A CURRENT DENSITY OF NOT OVER 300 CIRCULAR MILS
PER AMP.
C.
WELD CABLE
INSULATION WITH A VOLTAGE RATING TO WITHSTAND THE OPENCIRCUIT VOLTAGE (OCV) OF THE WELDING POWER SOURCE MUST BE USED. WHILE
MOST WELDING POWER SOURCES HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
100 VOLTS. SOME WELDING POWER SOURCES OF SPECIAL DESIGN MAY HAVE HIGH
ER OPEN-CIRCUIT VOLTAGE.
OM-267
Page
7
3-3.
WELD OUTPUT CONNECTIONS
DC Po~iti~e
(Figure 3-4)
To obtain the full rated output from this unit, it is necessary
to select, install, and maintain proper welding cables. Failure
in any of these areas may result in less than
to comply
satisfactory welding performance.
'
'
'
'
t~J
'
'
'
'
'
A
B
A
B
A
Ensure that the unit is completely shut down before
making
The POSITIVE and NEGATIVE weld output terminals
located on the lower portion of the front panel.
'
'
A
B
1000 AMP POSITION
079 746
are
If welding cables
should be
were
not
followed
'
'
'
'
'
'
'
'
'
'
'J
'
'
'
A
B
A
B
A
B
A
B
Figure
ordered with this unit, the steps
the best welding
to
ensure
It
is
C.
recommended
that
Weld
oc
1500 AMP POSITION
750 AMP POSITION
performance:
Negative
'
1500
listed
DC Positive
Negative
DC
Welding Cables
2.
'
DC Positive
any weld output connections.
Location
1.
'
1000 Ampere Models
U
B.
~
B
500 AMP POSITION
A.
DC N~5~t~o
DC Po~itiv~
Nog~i~e
DC
059 539
Ampere Models
3.4. Weld
Output
Connections
Output Connections
the
welding cables be kept as
short as possible, be placed close together, and be of
adequate current carrying capacity. The resistance of the
welding cables and connections causes a voltage drop
which is added to the voltage of the arc. Excessive cable
resistance may result in overloading as well as reducing
the maximum current output capability of this unit.
Prdper Operation is to a great extent dependent on the use
of welding cables and connections that are in good
condition and of adequate size.
When the weld output terminals are not bused together, 500
amperes of weld output is available between one A Positive
and A Negative output terminals of the 1000 ampere model.
Simultaneously, 500 amperes of weld output is available
between one B Positive and B Negative from the 1500
ampere model when similar connections are made. 1000
amperes of weld output is available between the A Positive
and A Negative or B Positive and B Negative output terminals
of the 1000 ampere model when the output terminals are
bused together. 1500 amperes of weld output is available
from the 1500 ampere model when similar connections are
made. These units are shipped with the bus bar iii place.
Use Table 3-2 as a guide for selecting correct cable size for
the anticipated maximum weld current which will be
used. Table 3-2 shows total cable length from the welding
power source to the resistance grid welding station. Select
the size cable that is recommended for the maximum
CAUTION
weld current that is to be used.
3.
Do not
4.
Use correct lugs on the weld cables to connect them to
the weld output terminals.
5.
Ensure that all connections areclean and tight.
use
damaged
or
output terminals. Consult applicable
SECTION 4
-
safety
codes.
OPERATION
4-1.
Ammeter A
.
If the positive output terminal of one section of this
power source is connected to the negative output
terminal of the other section, two times the normal
output voltage will exist between the remaining two
frayed cables.
POWER CONTROL SWITCH
(Figure 4-1)
Ammeter B
CAUTION
-Voltmeter B
Voltmeter
Depressing
not
the POWER CONTROL
S~tton
from
welding
remove
power
internal
source
electrical power
circuitry.
to
the
all
of
the
does
power
Completely terminate all
welding power source by
lockout procedures
before
employing machinery
attempting any inspection or work on the inside of the
If
Unit.
the welding power source is connected to a
disconnect switch, padlock the switch in an open
position. If connected to a fuse box, remove the fuses
and padlock the cover in the closed position, If the
is connected
unit
circuit breaker, or other
to
a
disconnecting device without locking facilities, attach
a
red tag to the device to
warn
others that the circuit
isbeingworkedon.
A
B
DC Positive
A
B
DC Negative
TB-079 824
Figure
Page 8
4-1. Front Panel
Depressing the POWER CONTROL START button will
energize the welding power source and place the unit in a
ready-to-weld status. The START button must be held in
momentarily to ensure that the fan is running at operating
speed. Depressing the POWER CONTROL STOP button will
shut the
welding
power source down.
RATED
4-2.
OVERLOAD PROTECTION
OUTPUT1
MODEL
2000
Thermostat TP1, located in the main transformer, is wired
into the contactor W coil circuit. Should overheating occur,
TP1 would open causing the contactor to drop out thereby
suspending all operations. If TP1 opens, allow the unit to
vi
cool before resuming operations.
C
Circuit breaker CB protects the welding power source from
excessive secondary current draw. Current transformer CT1
and CT2, located in the secondary of the main transformer,
sense the secondary current draw. Should overloading occur,
CB would open causing the contactor to drop out
suspending all operations.
~%%%
SI
%%%
w
0-
%~
GPS -1500
1500
C,
z
C
-I
%%~
SI
thereby
%%
GPS -10 00
1000
40
To place the welding power source in a ready-to-weld status
should this circuit breaker trip, the circuit breaker should be
manually reset. Should the circuit breaker continue to trip
after each reset, an internal problem in the circuitry is most
attempt any further
the trouble has been remedied.
probably present. Do
not
welding
80
90 100
Figure 4-2. Duty Cycle Chart
DUTY CYCLE
The duty cycle of a welding power source is the percentage
of a ten minute period that a welding power source can safely
be operated at a given output. This welding power source is
rated at 100 percent duty cycle. This means that the welding
power source can be safely operated at rated load contin
uously. Figure 4-2 enables the operator to determine the safe.
power source
output of the
4-4.
70
8-079 809
welding until
PILOT LIGHT
The pilot light PL1 indicates when the
is in a ready-to-weld status.
60
% DUTY CYCLE
4-5
4-3.
50
welding
power
source at
various duty cycles.
METERS
The meters
They
are
provided
are
to
IMPORTANT
welding operation.
voltage measure
monitor the
not intended for exact current or
These meters are internally connected to the output
The voltmeters will indicate the voltage at the
output terminals, but not necessarily the actual voltage at the
welding arc (due to cable resistance, poor connections, etc.).
The ammeters will indicate the current output of the unit.
ments.
Exceeding the indicated duty cycle will cause overheating and thereby damage to the welding power
terminals.
source.
SECTION 5- MAINTENANCE
factured with lifetime-lubricated sealed ball
attention should be
CAUTION
5-2.
Depressing the POWER CONTROL S1~OP button does
not
remove
power from all of the welding power
internal circuitry. Completely terminate all
source
electrical power to the welding power source by
before
lockout procedures
machinery
employing
attempting any inspection or work on the inside of the
unit. If the welding power source is connected to a
disconnect switch, padlock the switch in an open
position. If connected to a fuse box, remove the fuses
and padlock the cover in the closed position. If the
unit is connected to a circuit breaker, or other
disconnecting device without locking facilities, attach
red tag to the device to
is being worked on.
a
warn
and
no
INTERNAL CLEANING
Occasional blowing out or vacuuming of the dust and dirt
from around the internal components is recommended. This
should be done periodically depending upon the location of
the unit and the amount of dust and dirt in the atmosphere.
welding power source outer enclosure should be removed
a clean, dry air stream or vacuum suction should be used
for this cleaning operation.
The
and
5-3.
CONTROL CIRCUIT PROTECTION
control circuit of the welding power source is
a 600 volt, 3 ampere, cartridge type fuse Fl.
This fuse is located under the top cover beside contactor W.
entire
The
others that the circuit
protected by
Should
5-1.
bearings
required.
this
completely
FAN MOTOR
fuse open,
shut down.
the
welding
power
source
would
models are equipped with an exhaust fan and rely on
forced draft for adequate cooling. The fan motor is manu
All
SECTION 6
-
TROUBLESHOOTING
CAUTION
It
.1
the
Hazardous
circuitry of
is
voltages are present on
welding power source as long
the
connected
the
to
unit.
internal
as
power
Disconnect
power before
the inside of the
attempting any inspection or work on
unit. Troubleshooting of internal circuitry should
performed by qualified personnel only.
The
following
remedies
welding
for
chart
some
is
designed
to
diagnose
of the troubles that
ijy
and
rfovelop
be
provide
in this
is
power
installation
has been
that proper
made,
Section 3 of this manual, and that the welding
this
trouble
until
has been functioning properly
assumed
according
to
source
developed.
Use this chart in conjunction with the circuit diagram while
performing troubleshooting procedures. If the trouble is not
remedied after performing these procedures, the nearest
Factory Authorized Service Station should be contacted. In
all
of equipment malfunction, the manufacturers
cases
recommendations should be strictly followed.
power source.
OM-267 Page 9
TROUBLE
PROBABLE CAUSE
No output.
Thermostat TP1 open.
REMEDY
Allow unit
a
cooling period.
Replace defective TP1.
Fan motor switch FMS is open.
Hold START button in momentarily.
Fan
motor rpm is too
Replace defective fan
slow due to low input
voltage.
motor FM.
Replace defective FMS.
Circuit breaker CB open.
Reset CB.
Replace defective CB.
Replace defective
Fuse F 1 is blown.
1f it becomes necessary to
replace
any fuse in the
welding
power source,
ensure
that
a
F 1.
fuse of the proper size is used.
Circuit Diagram No. CB-902 383-lA
Figure 6-1. Circuit Diagram For 1000 Ampere Models
Page
10
TE1
I
LO
7
I
L
TE1
~RD.
45
NEGATIVE
A
NEGATIVE
Circuit
Figure 6-2. Circuit Diagram For 1500 Ampere
POSITIVE
Diagram No. CB.902 388.1A
Models
OM-267 Page 11
FORM: OM-267
August 1978
Effective With Serial No. HJ165871
MODEL
GPS- 1000
GPS- 1500
PARTS
LIST
Figure A
OM-267 Page 1
Left Side View
1
16
8
2
Quantity
Item
Dia.
Factory
No.
Mkgs.
Part No.
1
T2
036630
2
W
059720
*079 507
079 506
2
W
004104
*~O4 258
004 259
Wi
3
Fl
4
SR1,11
VS 1,2
11500
Left Side View
A
Figure
Model
1000
Description
034821
*604 259
012 638
079 827
024 471
TRANSFORMER, control 100VA 115-230/460
CONTACTOR, 120 amp 3 pole 600 volts (consisting of)
KIT, contact point
COIL, contactor 120/240 volts
CONTACTOR, 210 amp 3 pole 600 volts w/115 volts ac (consisting of)
KIT, contact point
COIL, contactor 120 volts ac
INTERLOCK, contactor normally open
FUSE, cartridge 3 amp 600 volts
HOLDER, fuse cartridge 30 amp 600 volts
RECTIFIER, silicon diode (consisting of)
1
-
-
SUPPRESSOR, 1 uf 2.7 ohm
2
2
Dl -6
037 157
.
Ci 1-16
031 689
.
SR1,11
059 685
Dl 1-16
DIODE, rectifier 275
amp 250 volts
straight polarity
24
Cl -6
4
CAPACITOR, ceramic 0.01 uf 500 volts dc (with leads)
RECTIFIER, silicon diode (consisting of)
6
2
Cl -6
Cl 1-16
031 689
-
CAPACITOR, ceramic 0.01 uf 500 volts dc (with leads)
6
Di -6
Dl 1-16
037 157
025 638
059 118
6
V1,2
Ai,2
Ai,2
7
PB1
011 636
8
PL1
*027 629
5
6
059 120
027 631
027 628
9
CB
034945
10
059 605
11
009 139
12
059 563
13
059 616
14
059 567
601 841
601 842
059 566
038 909
602 249
602 219
038 032
059 983
15
059 676
16
Shunt
079 388
16
Shunt
030635
17
FM
032633
FMS
011 850
FMS
052613
CT1,2
CT1,2
080075
036612
DIODE, rectifier 275 amp 250 volts straight polarity
METER, volt dc 0-100 scale
METER, amp dc 50 MV 0-800 scale.
METER, amp dc 50 MV 0-1k scale
SWITCH, push button start-stop 60 amp 110 volts
BULB, incandescant slide base 120 volts
HOUSING, light slide base 125 volts
LENS, light red clear
CIRCUIT BREAKER, manual reset 2P 5 amp 240 volts
18
2
2
-
-
-
ac
PANEL, front
VISOR, front top
BAFFLE, air top rectifier
BRACKET, mounting terminal board
TERMINAL ASSEMBLY, power output (consisting of)
NUT, brass hex jam 5/8-1 1
NUT, brass hex 5/8-1 1
TERMINAL BOARD, power output
STUD, brass 5/8-1 1 x 3
WASHER, flat steel SAE 5/8
WASHER, lock steel external tooth 5/8
-
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
16
-
-
-
-
.
BUS BAR
BUS BAR, jumper
BASE
-
8
2
2
8
8
8
8
8
8
4
4
secondary
SHUNT, meter 50 MV 800 amp
SHUNT, meter 50 MV 1000 amp
MOTOR, 1/4 hp 230 volts ac 1625 RPM (consisting of)
SWITCH, centrifugal (GE Motor) or
SWITCH, starting (Emerson Motor)
TRANSFORMER, current 300/5
TRANSFORMER, current 800/5
2
2
2
2
1
1
1
1
2
2
*Recmmeded Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-267 Page 2
Figure
Page 3
B
Right Side View
Quantity
Item
Dia.
Factory
No.
Mkgs.
Part No.
Figure B
030 691
R2,12
SR2,12
C8,18
604288
037513
30
C7,17
031 683
31
TEl
059555
28
29
031 640
601 375
038 897
602221
010910
601 837
TE2
038621
038 804
038 898
038 620
32
059 592
33
032616
34
059 585
014 425
35
Ti
35
Ti
079718
059575
**079 719
**059 576
**~79 529
**059 574
TP 1
11500
-
-
-
-
-
-
or
2
2
1
1
1
12
12
12
12
36
36
1
1
12
12
6
6
1
1
1
1
1
1
1
1
-
TRANSFORMER SUBASSEMBLY
1
TRANSFORMER SUBASSEMBLY
CLAMP
Factory
2
2
-
010014
003107
2
2
-
059 572
026 181
at
RESISTOR, carbon 1 watt 4700 ohm
RESISTOR,WWfixed i0watt2 ohm
RECTIFIER, selenium control
CAPACITOR, electrolyte 500 uf 200 volts dc
RING, mounting capacitor
CAPACITOR, paper oil 0.5 uf 200 volts dc
TERMINAL ASSEMBLY, primary (consisting of)
TERMINAL BOARD, primary
WASHER, lock steel internal tooth 3/8
WASHER, flat steel SAE 3/8
NUT, brass hex 3/8-16
BLOCK, terminal 30 amp 4 pole
STUD, brass 3/8-16 x 2-1/2
LINK, terminal connecting
LINK, jumper terminal block 30 amp
PANEL,rear
BLADE, fan 60 hz 20 inch 3 wing 21 degree
WINDTUNNEL,20inch
BAR, support windtunnel
TRANSFORMER, power main (consisting of)
TRANSFORMER, power main (consisting of)
COIL, primary/secondary
COIL, primary/secondary
THERMOSTAT, normally closed (located
PANEL, side
COVER,top
COVER, opening exit cable
059 559
**Replace
1000
Right Side View
Ri,i 1
27
Model
Description
-
1
6
6
in
coils)
6
6
2
2
1
1
1
1
2
Factory Authorized Service Station.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-267 Page 4
I