Download Miller Electric GPS-1500A Unit installation

I
January
1989
FORM: OM-267F
Effective With Serial No. JJ41 5979
F,, Millerfi
MODEL
GPS-1 000
GPS-1500A
GPS-1 500V
OWNERS
IMPORTANT
MANUAL
Read and understand the entire contents of this manual,
special emphasis on the safety material throughout the manual,
before installing, operating, or maintaining this equipment. This unit and
these instructions are for use only by persons trained and experienced in
the safe operation of welding equipment. Do not allow untrained persons
with
to
install, operate,
do not
or
Miller Electric
Mfg.Co.
AM,fle,Gro~,PLtdCon~Pany
P0. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
maintain this unit. Contact your distributor if you
fully understand these instructions.
PRINTED IN U.S.A.
ADDITIONAL COPY PRICE 80 CENTS
nil
L~MOTED WA~ANTY
EFFECTIVE: FEBRUARY 16, 1988
This warranty
supersedes
all
previous MILLER warranties
LIMITED WARRANTY
Subject to
and is exclusivewith
the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants
to its Distributor/Dealer that all new and unused
Equipment fur
nished by Miller is free from defect in workmanship andmaterial
as of the time and place of delivery by Miller. No warranty is
made by Miller with respect to engines, trade accessories or
other items manufactured by others. Such engines, trade ac
cessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are war
ranted by their manufacturer for one year from date of original
purchase, except Tecumseh engines which have a two year
warranty.
Except as specified below, Millers warranty does not apply to
components having normal useful life of less than one (1) year,
such as spot welder tips, relay and contactor points, MILLER
MATIC parts that come in contact with the welding wire includ
ing nozzles and nozzle insulators where failure does not result
from defect in workmanship or material.
Miller shall be required to honor warranty claims on warranted
Equipment in the event of failure resulting from a defect within
the following periods from the date of delivery of Equipment to
the original user:
1.
2.
3.
4.
Arc
welders, power
components
sources,
robots, and
1 year
Load banks
1 year
main power rectifiers
3 years
1 year only)
All welding guns, feeder/guns and torches
90 days
All other Millermatic Feeders
1 year
Replacement or repair parts, exclusive of labor 60 days
Batteries
6 months
6.
7.
provided that Miller is notified in
the date of such failure.
As a matter of general
submitted by the original
_~1
L
other guarantees
or
warranties
expressed
or
implied.
of Millers breach of warranty or any other duty with
quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases,
(3) the reasonable cost of repair or replacement at an author
ized Miller service station or (4) payment of or credit for the pur
chase price (less reasonable depreciation based upon actual
use) upon return of the goods at Customers risk and expense.
MILLERs option of repair or replacement will be FOB., Fac
tory at Appleton, Wisconsin, or FOB. at a MILLER authorized
service facility, therefore, no compensation for transportation
costs of any kind will be allowed. Upon receipt of notice of ap
parent defect or failure, Miller shall instruct the claimant on the
warranty claim procedures to be followed.
respect
case
to the
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
WARRANTY, GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL EQUIPMENT FUR
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
AND ANY IMPLIED
Original
(labor
..
5.
In the
no
writing within thirty (30) days of
policy only,
user
Miller may honor claims
within the foregoing periods.
EXCEPT AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTI
MATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS
AND FOR OPERATION BY PERSONS TRAINED AND EXPE
RIENCED IN THE USE AND MAINTENANCE OF WELDING
EQUIPMENT AND NOT FOR CONSUMERS OR CON
SUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
J Li
July 11,
1989
FORM: OM-267F
ERRATA SHEET
After this
to data
manual was printed, refinements
appearing
In
equipment design occurred.
This sheet lists
exceptions
later In this manual.
PARTS LIST
AMENDMENT TO SECTION 8
Amend Parts List as follows:
Quantity
Dia.
**
29-
2929-
29-
**First
Mkgs.
TE2
038
092
092
092
With
Deleted
130 165
130 162
130 164
621
301
300
295
digit represents page
Model
Replaced
Part
No.
no
-
100011 500A Ii 500V
Description
1 000A Model only (Eff w/JK638859)
COIL, pri/sec 230/460 (Eff w/JK642601)
COIL, pri/sec 230/460/575 (Eft w/JK642601)
COIL, pri/sec 460 (Eff w/JK642601)
digits following dash represent item
no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
6
6
6
TABLE OF CONTENTS
Section No.
SECTION 1
1-1.
Page
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-3.
Introduction
General Precautions
Arc Welding
1-4.
Standard Booklet Index
1-2.
SECTION 2
2-1.
1
1
7
11
INTRODUCTION
2-2.
Volt-Ampere Curve
Duty Cycle
2-3.
General Information And
2-4.
Receiving-Handling
Description
2-5.
SECTION 3
14
14
Safety
14
14
14
UNIT INSTALLATION AND RELOCATION
3-1.
Location
15
3-2.
Weld
15
3-3.
Output Connections
Electrical Input Connections
17
SECTION 4- OPERATOR CONTROLS
4-1.
Start And
4-2.
Pilot
4-3.
Meters
SECTION 5
5-1.
5-2.
Stop Push-Button Switch
20
20
Light
20
SEQUENCE OF OPERATION
Unit Preparation For
Shutting Down
Operation
20
20
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
21
6-2.
Fan Motor
21
6-3.
6-4.
Overload Protection
Thermal Protection (Thermostat
6-5.
Troubleshooting
SECTION 7
21
TP1)
22
22
ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
SECTION 8
No.
7-1. Circuit
23
7-2. Circuit
23
7-3.
24
Diagram For GPS-1 000 Models
Diagram For GPS-1500A Models
Circuit Diagram For GPS-1500V Models
PARTS LIST
Figure
Figure
8-1
Left Side View
26
8-2
Right Side
28
View
LIst Of Charts And Tables
Table 2-1.
Chart 2-1.
Chart 2-2.
Specifications
Volt-Ampere Curve
Duty Cycle
14
15
13
13
Table 3-1.
Weld Cable Size
Table 3-2.
Input Conductor And Fuse Size
19
Table 6-1.
Maintenance Schedule
21
Chart 6-1.
Troubleshooting
22
SECTION 1
SECTION 1
1-1.
-
-
REGLES
INTRODUCTION
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
DE
-
SECURITE POUR LEFONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
We
learn
by
experience.
1-1. INTRODUCTION
Contrairement a lappren
de Ia vie, lapprentissage de Ia sØcuritØ par ex
perience personnelle, comme lenfant qui touche un
-
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
tissage
wise. Let the
poŒle chaud,
experience
of others teach you.
dangereux,
est
imprudent
lnstruisez-vous donc de lexpØrience
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason 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.
et
inutile.
dautrui.
Des mØthodes de sØcuritØ issues de lexpØrience du
soudage et du coupage sont dØcrites dans le manuel. La
recherche, le progres et IexpØrience dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes de
sØcuritØ pour linstallation, le fonctionnement et lentre
tien. Des accidents se produisent lorsque le materiel est
inadequatement utilisØ ou entretenu. La raison de ces
mØthodes de sØcuritØ peut ne pas Œtre toujours donnØe.
Certaines sont fondØes sur le sens commun, dautres
demanderont a Œtre expliquØes par des livres techni
ques. II est plus sage de suivre les regles.
Read and understand these safe practices before at
Lisez et comprenez
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
dessayer dinstaller, de faire fonctionner ou de rØparer
Pour votre sØcuritØ personnelle et celle~
lappareil.
dautrui, conformez-vous a ces rŁgles et aux manuels
Failure
to
serious
injury
observe
or
the equipment
these
safe
practices may cause
death. When safety becomes a habit,
can
be used with confidence.
mØthodes de sØcuritØ avant
ces
dinstructions.
Manquer dobserver ces mØthodes de sØcuritØ pourrait
entrainer des blessures graves ou mØme Ia mort. Quand
Ia sØcuritØ devient une habitude, le materiel peut alors
Œtre utilisØ en toute confiance.
practices are divided into two Sections:
General Precautions, common to arc welding and
cutting; and 2 Arc Welding (and Cutting) (only).
Ces mØthodes de sØcuritØ sont divisØes en deux sec
1
tions:
Precautions gØnerales,
communes
au
soudage et au coupage a larc, et 2 Soudage a larc
(et coupage) (uniquement).
Reference standards: Published Standards on safety are
also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
Normes de rØfØrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opØratoires plus complets que
pour dautres
ceux du present manuel. Elles sont donnØes dans Iln
dex des Normes de ces rŁgles de sØcuritØ. ANSI Z49-1
est Ia plus complete.
These safe
1
-
-
most
complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide
ment installation, use, and service.
a
basis for
equip
-
-
Les
stallation,
1-2.
1-2. GENERAL PRECAUTIONS
Different
arc
and fluxes
welding processes, electrode alloys,
produce different fumes, gases,
can
and radiation levels. In addition to the information
manual, be
in this
sure
to consult flux and elec
trode manufacturers for
and
precautionary
specific technical data
concerning their
measures
IACNOR,
de
une
utilisation
les
les
et un
codes
provinclaux
exigences
pour
entretien sOrs.
une
et
in
PRECAUTIONSGENERALES
Plusieurs procedes du soudage a larc, des Ølec
trodes allies, et les flux peuvent produire des
niveaux
et
de
vapeurs,
gaz,
rayonnement
diffØrents. Pour tout renseignement supplØmen
taire a ce manuel, consultez aussi lee fabricants
des electrodes et des flux afin dobtenir
lee
renseignements
mesures
de
techniques spØcifiques
precaution
concernant
lee
leurs
et
matriaux.
material.
A.
A.
codes
municipaux donnent aussi
Prevention des brOlures
Burn Prevention
Portez des vŒtements de
protective clothing gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuff less trousers
to avoid entry of sparks and slag.
Wear
-
protection
des gants a crispin
un casque et
des chaussures de sØcuritØ. Boutonnez le col de votre
chemise et les pattes de vos poches, et portez des pantalons sans revers pour Øviter que des Øtincelles et dii
laitier ne sy introduisent.
spØcialement dØsignØs
pour le
-
soudage,
Wear helmet with
safety goggles or glasses with side
underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
shields
welding
or
cutting, (and chipping)
to
protect the eyes
Portez un masque avec lunettes de sØcuritØ ou avec
Øcrans latØ-raux de protection, des lunettes filtrantes ou
des couvre-lentilles (proteges par un verre clair). Pour le
soudage ou le coupage (et le burinage), il est
OM-267
Page
1
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid
oily
or
Hot metal
should
greasy
such
never
as
ses
yeux contre
lØnergie
projections.
electrode stubs and
workpieces
Evitez de porter des habits imprØgnØs dhuile
graisse. Une Øtincelle pourrait les enflammer.
be handled v~ithout
gloves.
mediate treatment of flash burns of the eyes and skin
should be worn when working on overhead or
confined space. A hard hat should be worn when
others work overhead.
plugs
de
verre
des
Voir 1.3A.2.
ignite them.
burns.
Ear
protØger
rayonnement et les Øclats de metal. Remplacez le
protecteur lorsquil est brisØ, piquØ ou quil a reu
may
clothing. A spark
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im
in
OBLIGATOIRE de
ou
de
Ne manipulez jamais sans gants un metal chaud tel que
des chutes dØlectrode et des piŁces a souder.
Premiers soins et traitement des yeux: Tout atelier
devrait avoir a sa disposition un poste de premiers soins
ainsi quune personne compØtente, a moms quur, ser
vice medical ne soit a proximitØ pour soigner immediate
ment les brlures des yeux et de Ia peau.
a
Flammable hair preparations should not be used by per
intending to weld or cut.
Les personnes devant souder
sons
Severe discomfort,
illness
or
ou
couper
ne
employer des preparations inflammables
Toxic Fume Prevention
B.
Portez des bouche-oreilles lorsque vous travaillez au
plafond ou dans un espace restreint. Portez un casque
lorsque dautres personnes travaillent au plafond.
doivent pas
pour leurs
cheveux.
death
result from
can
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
adequate ventilation as described in ANSI Stan
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
with
B.
Prevention des gax toxiques
Les gaz, les vapeurs, Ia chaleur, un enrichissement ou
peuvent entraIner un malaise,
manque doxygŁne
une maladie ou mŒme Ia mort. RemØdiez-y par Ia ven
tilation dØcrite dans Ia Norme ANSI Z49.1 paragraphe 1
de lIndex
des Normes. NE ventilez JAMAIS a lox
un
ygŁne.
Lead
cadmium
-,
zinc
-,
mercury
-,
-,
beryllium
and
-
bearing and similar materials, when welded (or cut) may
produce harmful concentrations of toxic fumes. Ade
quate local exhaust ventilation
person in the
area as
well
air-supplied respirator.
as
For
must be
used,
the operator must
beryllium, both
or
each
wear an
must be us
ed.
En soudant
mercure
et
ou en
coupant, les plomb, cadmium, zinc,
ou autres matØnaux semblables
beryllium
peuvent crØer des concentrations nocives de gaz toxi
ques. On doit avoir recours a une ventilation aspirante
adequate du local, ou alors toute personne sur les Iieux,
de mŁme que le soudeur, doit porter un masque a ad
On doit employer les deux pour le
duction dair.
beryllium.
Metals coated with
containing materials
or
toxic fumes should not be heated unless
removed from the work
tilated,
or
the operator
that emit
coating is
area is well ven
surface,
air-supplied respirator.
the
wears an
Work in
a confined space only while it is
tilated and, if necessary, while wearing an
being ven
air-supplied
respirator.
Les mØtaux enrobØs Cu composes de matØriaux Ømet
des gaz toxiques ne doivent pas Œtre chauffØs a
tØ
de Ia surface a
moms que lenrobage
ne soit
travailler, que le local ne soit bien ventilØ, cu que le
soudeur ne porte un masque a adduction dair.
tant
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
leaks
Gas
in
a
confined
space should
be
avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a
confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
to
left open. Check
re-entering it.
to
be
sure
that the space is safe before
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 pro
ducts. The ultraviolet (radiant) energy of the arc can
decompose trichloroethylene and per
also
vapors to form phosgene. DO NOT
where solvent vapors can be drawn into
or cutting atmosphere or where the radiant
chioroethylene
WELD
the
OM-267
or cut
welding
Page
2
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantitØ peuvent
transformer dangereusement Ia concentration dox
ygene. Namenez pas de bouteilles de gaz dans un
espace restreint.
En quittant un espace restreint, FERMEZ le robinet
dalimentation de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme si les
robinets aval
ont ØtØ ouverts par accident, ou si on tes
a laissØs ouverts.
Les vapeurs de dissolvants chlorØs peuvent Œtre dØcom
par Ia chaleur de larc (ou de Ia flamme) et
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant les poumons et les yeux. LØnergie
ultra-violette de larc peut aussi dØcomposer les vapeurs
de trichloroØthylŁne et de perchloroethylŁne pour
posØes
former du phosgene. NE SOUDEZ PAS ou ne coupez
pas dans des endroits oCa les vapeurs de dissolvants peu
vent Œtre attirØes dans IatmosphŁre de soudage ou de
minute
atmospheres containing
trichioroethylene or
to
penetrate
can
energy
of
amounts
even
per
chloroethylene.
coupage et oCi lenergie de rayonnement peut pØnØtrer
dans des atmospheres contenant des quantites mºme
de
minuscules
trichloroethylŁne ou de per
chloroethylŁne.
Explosion Prevention
Fire and
C.
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.
BE 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.
To prevent fires and
Prevention des incendies et des
C.
explosion:
explosions
Les causes dincendie
et dexplosion
sont les com
bustibles atteints par larc, Ia flamme, les Øtincelles, le
laitier chaud ou les matØriaux chauffØs, le mauvais
emploi des gaz comprimØs et des bouteilles ainsi que les
courts-circuits.
Sachez que les Øclats dØtincelles ou Ia chute du laitier
sinfiltrer
dans les fissures, le long des
tuyauteries, par les fenŒtres et les portes et par les
couvertures des murs ou du sol, sans que le soudeur
portant des lunettes ne les voie. Les Øtincelles et les
35 pieds.
scones peuvent voler jusqua
peuvent
Pour
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause
short circuits.
prØvenir les incendies et les explosions: Veillez a ce
appareil soit propre et en Øtat de marche,
dØnuØ dhuile et de graisse, et de particules de metal sur
les piŁces electriques qui pourraient entraIner des
que votre
courts-circuits.
in area, do NOT weld or cut. Move
practicable, to an area free of combustibles.
If combustibles
the work if
are
paint spray rooms, dip tanks, storage areas, yen
tilators. If the work cannot be moved, move com
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
Avoid
snug-fitting,
fire-resistant
covers or
shields.
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.
standing by with suitable fire ex
tinguishing equipment during and for some time after
welding or cutting if:
Fire watcher must be
Si des combustibles
a proximitØ, ne soudez
possible, dØplacez votre travail
loin des combustibles. Evitez les ateliers de peinture au
pistolet, les cuves dimmersion1 les entrepOts, les yen
tilateurs. Si cela nest pas possible, placez les com
bustibles a au moms 35 pieds des Øtincelles et de Ia
chaleur et protØgez-les des Øtincelles avec des couver
tures ou des Øcrans protecteurs adØquats, bien ajustØs
et ignifugØs.
On
doit pas souder (ou couper) le ctØ oppose des
touchant les combustibles. Les murs, plafonds et
planchers proches du travail doivent Œtre protØgØs par
des couvertures ou Øcrans protecteurs ignifugØs.
ne
murs
Un surveillant dolt se tenir a proximitØ avec un materiel
de lutte contre lincendie adØquat, pendant et quelque
temps aprØs le soudage ou le coupage si:
a.
a.
appreciable combustibles (including building
are within 35 feet
combustibles
are further than 35
appreciable
feet but can be ignited by sparks
openings (concealed or visible) in floors or
construction)
b.
c.
walls
within
35
feet
may
expose
b.
c.
com
sparks
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
bustibles to
d.
radiant
or
d.
conducted heat.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
have been taken.
After work is done, check that
glowing embers, and flames.
area
is free of
sparks,
never
be welded
been cleaned
as
on
or
cut, unless container has first
in AWS Standard 46.0,
described
listed 7 in Standards index.
Des quantites apprØciables de combustibles
(y compris une construction en chantier) se
trouvent a moms de 35 pieds.
Des quantitØs apprØciables de combustibles
sont a plus le 35 pieds mais peuvent Œtre
enflammØes par des Øtincelles.
Des ouvertures (cachØes ou visibles) sur les
planchers ou les murs a moms de 35 pieds
peuvent exposer des combustibles aux
Øtincelles.
Les
combustibles adjacents aux
murs,
plafonds, toits ou cloisons mØtalliques peu
vent Œtre enflammØs par une chaleur rayon
nante ou transmise.
Avant de commencer, avisez le contrernaItre pour quil
sassure que les precautions adØquates soient prises.
Une fois le travail terminØ, vØrifiez quil ny ait pas
dØtincelles, de cendres ardentes ou de flammes dans le
local.
On
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
se trouvent
coupez pas. Si
ne
pas,
ne
dolt
jamais
des
souder ni couper
combustibles,
sur
un
recipient
pouvant produire
des vapeurs inflammables ou toxiques a Ia chauffe, a
moms que le recipient nait ØtØ lavØ au prØalable, cornme dØcrit dans Ia Norme AWS A6.0,
figurant au
paragraphe 7 de llndex des Normes.
ayant
contenu
ou
Cela
This includes:
a
solvent
or
thorough steam or caustic cleaning (or
water washing, depending on the corna
comprend: un nettoyage a fond a Ia vapeur ou au
caustique (ou un lavage avec dissolvant ou eau selon Ia
solubilitØ du combustible) suivi dune
purge et dune
OM-267
in-
Page
3
bustibles
solubility) followed by purging and inerting
nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.O. Wateruilling just
below working level may substitute for inerting.
with
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
or sight to determine if it is safe to weld or cut.
smell
jection dazote ou de gaz carbonique, en utilisant un
Øquipement de protection comme recommandØ dans
lA6-O. LatmosphŁre inerte peut Œtre remplacØe par un
arrivant au-dessous du travail a effectuer.
niveau deau
Vous devez layer un recipient dont Ia nature de contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS Ł lodorat ou a Ia vue pour dire si lon peut le
souder ou le couper en toute sØcuritØ.
Vous devez pratiquer
Hollow
castings or containers must be
welding or cutting. They can explode.
Explosive atmospheres. Never
may contain flammable
as
weld
dust, gas,
vented before
or cut
where the air
liquid
vapors (such
or
gasoline).
pients creux
exploser.
un
event
sur
les piŁces
avant de les souder ou couper: ils
ou
rØci
peuvent
Atmospheres explosives: Ne soudez ni ne coupez
jamais dans des lieux oij lair peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
que Iessence).
D.
Compressed
Gas
Equipment
D.
Gaz comprimØ
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, SAFE
Precautions gØnØrales: Suivez les precautions de ce
manuel, et celles dØcrites a Ia Norme CGA P-i (PrØcau
HANDLING
tions de sØcuritØ pour Ia
OF
COMPRESSED
GASES
CYLINDERS, listed ii in Standards index.
IN
en
1.
1.
Pressure
Regulators
manipulation
de gaz comprimØs
des Normes.
bouteilles), paragraphe ii de llndex
DØtendeurs de
pression
La soupape de sOretØ dun dØtendeur est destinØe a pro
le dØtendeur de Ia surpression. Elle na
pas pour but de proteger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes de retenue conues
spØcialemerit pour cette fonction.
teger seulement
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream equipment. Provide such protec
tion with
one or more
relief devices.
Ne
Never
connect a
regulator
other than that for which the
Remove
faulty regulator
cylinder containing gas
regulator was designed.
to a
from service
immediately
repair (first close cylinder valve). The following
faulty regulator:
for
symp
toms indicate a
if gas leaks externally.
if delivery pressure continues to rise
Excessive Creep
with downstream valve closed.
Faulty Gauge if gauge pointer does not move off stop
Leaks
-
-
-
pin when pressurized,
nor
returns
to
stop pin after
pressure release.
Repair. Do NOT attempt repair. Send faulty regulators
repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
for
2.
Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
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 ac
cident. (See 1-3C.)
montez
jamais
un
dØtendeur
sur une
gaz different de celui pour
ØtØ conu.
nant
un
bouteille conte
le dØtendeur a
lequel
Enlevez immØdiatement un dØtendeur dØfectueux pour
le faire rØparer (dabord,
fermez le robinet de Ia
bouteille). Les symptmes suivants dØnotent Ia dØfec
tuositØ du dØtendeur:
Fuites Si le gaz fuit extØrieuremerit.
Ascension excessive si Ia pression de debit continue a
monter, le robinet du chalumeau Øtant fermØ.
ManomŁtre dØfectueux
si laiguille du manomŁtre ne
sØcarte pas de Ia goupille de butØe lors de Ia mise en
pression, ou ne revient pas sur Ia goupille aprŁs lØchap
pement de (a pression.
-
-
-
Reparation. NESSAYEZ PAS de rØparer vous-mŒmes.
Envoyez les dØtendeurs dØfectueux a rØparer aux
ateliers de reparation agrees du fabricant, o des techni
ques et des outils spØciaux sont utilisØs par un person
nel formØ.
2.
Bouteilles
Les bouteilles doivent Œtre manipulØes avec soin pour
prØvenir les fuites ou dØgªts a leurs parois, robinets ou
systŁmes de sQretØ. Evitez quun circuit Ølectrique soit
en contact avec les bouteilles, y compris les rails de con
tact, les fils Ølectriques ou les circuits de soudage. Cela
pourrait crØer des arcs courts-circuits pouvant entrainer
des accidents graves (Voir i.3C.).
ICC
or
marking must be on each cylinder. It is an
of safety when the cylinder is properly
DOT
assurance
handled.
OM-267 Page 4
Chaque bouteille
dolt porter les inscriptions ICC ou
DOT. Cest un gage de sØcuritØ pourvu que Ia bouteille
soit bien manipulØe.
Identifying gas content. Use only cylinders with name
of gas marked on them; do not rely on color to identify
gas content. Notify supplier if unmarked. NEVER
Identification du gaz: Nutilisez que les bouteilles mdi
quant Ia nature du gaz; ne vous fiez pas a Ia couleur
DEFACE
votre
cylinder.
alter name, number, or other
It is illegal and hazardous.
or
markings
on a
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited
use.
Never
use a
cylinder
or
other than its intended use, NEVER
roller.
Locate
or secure
cylinders
so
they
its contents for
as
a
support
NEFFACEZ
modifiez
ne
ou
numØros ou autres indications
est
illegal
over.
clear of
excessive heat, sparks,
rupture. Do not
allow contents to exceed 130F. Cool with water spray
where such exposure exists.
Do NOT expose
cylinders
to
etc. that may cause
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
interdit: Nutilisez
ce a quoi elle est
support ou rouleau.
a
cylinder valve that
supplier.
hammer
use a
can not
be
or
opened
wrench to open
by hand. Notify
bouteille
Emploi
une
que pour
destinØe, mais JAMAIS
me
ou son contenu
Placez les bouteilles pour quelles ne tombent
quun dØtendeur (et un boyau) est monte
placez les ou attachez-les debout.
com
pas. Lors
sur
elles,
et Iieux de travail. Enlevez les bouteilles dun
lon pourrait les frapper.
endroit o
des bouteilles. Avec une grue, utilisez un sup
plate-forme ou un cadre. NE
port fiable tel quune
SOULEVEZ PAS des bouteilles du sol par leur robinet
ou chapeau, ou avec des chaInes, Ølingues ou aimants.
Transport
PAS les bouteilles a une chaleur excessive,
au laitier et aux flammes, etc., pouvant
Ieur rupture. Le contenant ne doit jamais
causer
dØpasser 55C. Refroidissez en pulvØrisant de leau si
nØcessaire.
NEXPOSEZ
Øtincelles,
aux
ProtØgez les bouteilles
contre les
Stuck valve. Do NOT
dangereux.
Vides: Maintenez les robinets fermØs, replacez bien les
chapeaux; inscrivez ~Vides; sØparez-les des Pleines
et retournez-les rapidement.
Passages
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
slag, and flame,
et
JAMAIS les noms,
une bouteille. Cela
sur
or
cannot be knocked
Passageways and work areas. Keep cylinders
areas where they may be struck.
Ia nature du gaz. Adressez-vous a
fournisseur si cela nest pas indiquØ.
pour reconnaitre
et
particuliŁrement les soupapes
chocs, les chutes, les chutes dobjets
temperature. Remettez bien les chapeaux lorsque
dØplacez les bouteilles.
et
Ia
vous
your
Robinet coincØ. NUTILISEZ
Mixing
gases. Never try to mix any gases in
Never refill any
cylinder.
a
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
MØlange
dans
3.
Prohibited
use.
Never
specified gas.
use
A
hose other than that
general
gases.
tubing splices.
splice hose.
No copper
Use
only
standard brass fit
Avoid
long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil
une
3.
excess
de gaz.
Nessayez jamais de mØlanger des gaz
bouteille.
Boyau
Utilisation interdite.
que celui
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
to
marteau ou une
designed
hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
tings
un
Ne rechargez jamais u~ne bouteille. Les ØlØments de Ia
bouteille ne doivent jamais Œtre modifies ou remplacØs.
Hose
for the
PAS
clØ mØtallique pour ouvrir un robinet de bouteille que
Ion ne peut pas ouvrir a Ia main. Avisez votre four
nisseur.
hose to prevent kinks and
tangles.
appropriØ
Nutilisez
jamais
un
boyau
autre
gaz indiquØ. La regle generale
didentification est: rouge pour les gaz combustibles,
vert pour loxygŁne,
et noir pour les gaz inertes.
au
Utilisez des bagues ou colliers appropriØs au boyau (et
du fil ordinaire ou autre substitution) pour brancher
les boyaux a lappareillage.
non
Nutilisez pas des raccords en cuivre. Nutilisez que des
accessoires standard en laiton pour raccorder un boyau.
Utilisez une petite longueur de boyau. Cela Øvitera les
noeuds et lusure prØmaturØe. Suspendez le boyau au
dessus du sol pour Øviter quil ne soit ØcrasØ, piØtinØ ou
endommage.
Protect hose from
sparks, slag, and
Examine hose
damage by sharp edges,
and
by
open flame.
regularly for leaks, wear, and loose con
pressured hose in water; bubbles in
Enroulez le surplus de boyau pour Øviter les noeuds et
emmŒlements. Evitez que le boyau ne soit endommage
par des tranchants, Øtincelles, laitier et flamme flue.
nections. Immerse
dicate leaks.
OM-267
Page
5
Repair leaky
ing (1-2D3).
4.
or worn
Do NOT
hose by
use
cutting
area out
and
splic
tape.
Proper Connections
Clean cylinder valve outlet of impurities that may clog
seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
VØrifiez rØguliŁrement es fuites, lusure
et les rac
cordements lØches. Plongez le boyau sous pression
dans de Ieau; les bulles indiqueront les fuites.
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØsif.
orifices and damage
outlet away from people and
with a clean lintless cloth.
sources
of
ignition. Wipe
Match regulator to cylinder. Before connecting, check
regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
that the
a regulator designed for a particular
cylinder containing any other gas.
NEVER CONNECT
gas
or
gases to
Tighten
a
connections. When assembling threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
4.
Branchements corrects
Avant de brancher le dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteille des impuretØs qui peuvent
obstruer les orifices et endommager les sieges. Sauf
ouvrez momentanØment le robinet,
pour lhydrogŁne,
eloignant
en
flammables.
Ia sortie des personnes et des sources inEssuyez avec un tissu propre et non
graisseux.
Appareillez le dØtendeur a Ia bouteille. Avant de bran
cher, vØrifiez que Ia marque du dØtendeur et Ia descrip
tion de Ia bouteille concordent, et que )orifice dentrØe
du dØtendeur et Iorifice de sortie de Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
concu pour un gaz special (ou des gaz spØciaux) a une
bouteille contenant dautres gaz.
Serrez les branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges oU
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-les, nettoyez et resserez avec une clef adØ
quate.
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
Adaptateurs. Placez, si
(en
vente chez votre
dØterideur. Avec deux
5.
Pressurizing Steps:
regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Drain
Stand
to side
of
regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stemagainst possible leak. For fuel gas,
open to less than one turn to permit quick emergency
creases
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E.
User
Responsibilities
leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
Remove
*Trademark of Proctor & Gamble
OM-267 Page 6
besoin est,
fournisseur)
clefs,
un
entre
serrez
adaptateur CGA
Ia bouteille et le
Iadaptateur filetØ A
DROITE et A GAUCHE.
On peut reconnaitre les branchements de sortie du
dØtendeur (ou boyau) a laide du filetage a droite pour
loxygŁne et a gauche (identifiØ par un Øcrou cannelØ)
pour les gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur de rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet de canalisation) en serrant Ia vis
de reglage (dans le sens des aiguilles dune montre).
Cette operation permet au siege de haute pression de
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez Ia vis de rØglage
des dØtendeurs a simple dØtente lØgerement engagØe.
Avant douvrir Ie robinet de Ia bouteille, assurez-vous
que les boyaux sont branches et que les soupapes aval
sont fermØes.
Tenez-vous latØralement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-le lentement pour que Ia
pression du dØtendeur monte progressivement. Lorsque
le manomŁtre est mis sous pression (indique le max
imum) le robinet de Ia bouteille de gaz inerte ou dox
ygene devra Œtre ouvert a fond pour assurer lØtanchØitØ
et celui de Ia bouteille de gaz combustible ouvert de
moms dun tour pour pouvoir le refermer rapidement en
cas
durgence.
RØfØrez-vous
tableaux de pression (distribuØs par
un
reglage recommandØ de
pression sOr et efficace sur les dØtendeurs. VØrifiez les
fuites a Ia premiere mise en pression puis rØguliŁrement,
brossez avec une solution savonneuse (un bouchon
dlvory Liquid* ou semblable par gallon deau). Les
bulles indiquent une fuite. Enlevez leau savonneuse
aprŁs examen; le savon sec est inflammable.
votre
aux
fournisseur) pour
Marque de Commerce
de Proctor & Gamble
F.
Leaving Equipment
Close gas supply at
source
Unattended
ResponsabilitØs de lusager
E.
Otez immØdiatement les parties percØes
Voir les ResponsabilitØs de lUsager
de lappareil.
and drain gas.
tueuses.
G.
Rope Staging-Support
Rope staging-support should
cutting operation; rope may
1-3. ARC WELDING
is
a
used for
welding
safe process, but a careless operator invites trouble.
equipment carries high currents at significant
ed. The wise operator avoids unnecessary risks and pro
himself and others from accidents. Precautions
tects
described here and in standards referenced in index.
A.
Burn Protection
Comply
with
Appareil
laissØ
Fermez lalimentation
-
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
are
F.
or
sans
dØfec
surveillance
burn.
Comply with precautions in
section. Arc Welding, properly done,
1-1, 1-2, and this
The
not be
ou
du manuel
precautions in 1-2.
The
welding arc is intense and visibly bright. Its radia
can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
G.
de gaz a Ia
Liens et supports
source et
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
1-3. SOUDAGE A LARC
Confprmez-vous aux
precautions des paragraphes 1.1 et 1.2 de cette section.
Le soudage a larc
bien exØcutØ est sOr, mais un
soudeur negligent est un danger. Le poste de soudage
transporte des courants ØlevØs sous de fortes tensions.
Larc est trŁs vif et chaud. Les Øtincelles volent, les
vapeurs montent, lØnergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrul contre
les accidents. Les precautions sont dØcrites ici et dans
les normes donnØes dans llndex.
-
tion
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DONT
GET
COMPLY
BURNED;
WITH
PRECAU
TIONS.
1.
Protective
Wear
Clothing
long-sleeve clothing (particularly
for
gas-shi&ded
A.
Protection
contre
les brUlures
Conformez-vous aux precautions du paragraphe 1 .2.
Larc de soudage est intense et visiblement vif. Son
rayonnement peut blesser les yeux, traverser les habits
lØgers, se rOflØchir sur les surfaces claires, et brler Ia
peau et les yeux. Les brOlures de Ia peau ressemblent a
un gros coup de soleil. Celles darcs
sous gaz protecteur
sont plus graves et plus douloureuses.
NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
1.
VŒtements de
protection
leather
jacket or sleeves, flame-proof apron, and f ireresistant leggings. Avoid outergarments of untreated
cotton.
Bare skin
protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2.
Eye and Head Protection
Protect eyes from exposure to
arc without protection.
arc.
NEVER look at
an
electric
Welding helmet
no.
over
12
Portez des vŒtements a manches longues (surtout pour
larc en atmosphere inerte) avec gants, masque et
chaussures (1.2A.).
or
or
shield
containing
a
face before
striking
Protection de Ia peau. Portez des vŁtements Øpais
foncØs. Boutonnez le col pour protØger Ia poitrine et le
cou, et boutonnez les poches pour prØvenir linfiltration
dØtincelles.
filter
denser must be used when
plate shade
welding. Place
Si nØcessaire portez en plus urie veste ou des manches
cuir, un tablier et des guŒtres ignifugØs. De
preference ne portez pas de vŁtements en coton non
traitØ.
en
2.
Evitez
Protect filter
Cracked
or
plate with
a
clear
broken helmet
worn; radiation can pass
Cracked, broken,
IMMEDIATELY.
broken, pitted,
or
Protection des yeux et de Ia tŒte
arc.
or
cover
plate.
shield should NOT be
through
to cause burns.
loose filter plates must be replaced
Replace clear cover plate when
spattered.
que
JAMAIS
vos
yeux soient
un arc
electrique
exposØs a larc. NE regardez
sans protection.
vous soudez, portez un Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-Ie sur le
visage avant damorcer Iarc.
Lorsque
verre
or
le verre filtrant dun
couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ment peut sinfiltrer et causer des brlures.
Protegez
Les
verres
filtrants
fendus, brisØs
ou
Iches
doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez un couvre
verre brisØ, piquØ ou tachØ par des projections.
OM-267
Page
7
Flash
goggles
the helmet to
with side shields MUST be
give
protection
some
the helmet not be lowered
over
worn
to the eyes
the face before
under
should
an arc
is
Looking at an arc momentarily with unprotected
(particularly a high intensity gas-shielded arc) can
struck.
eyes
retinal burn that may leave
cause a
area
a
permanent dark
in the field of vision.
Vous devez portez des lunettes a Øcrans latØraux sous le
masque pour protØger les yeux dans le cas o le masque
de
ne serait pas abaissØ sur le visage avant lamorcage
larc. Regarder momentanØment un arc sans protection
(principalement un arc en atmosphere inerte a haute in
tensitØ) peut brt~ler Ia rØtine et laisser un point sombre
permanent dans le champ de vision.
Protection du
3.
3.
Protection of Nearby Personnel
welding
Enclosed
For
area.
production welding,
enclosed bay is best. In open areas,
with low-reflective,
noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
separate
room or
the
surround
Viewing
operation
the weld. Provide face shields for all persons
looking directly at the weld.
who will be
Others working in
flash
area.
See that all persons
wearing
goggles.
Before starting to weld, make
bay doors are closed.
B.
are
sure
that
screen
flaps
le soudage de produc
utiliser une salle sØparØe ou une bale
fermØe. Dans les locaux ouverts, entourez les travaux
dØcrans ou panneaux peu rØflØchissÆnts et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
Local de
a
personnel a proximitØ
tion, il
soudage fermØ. Pour
vaut mieux
Donnez des masques aux personnes
directement Ia soudure.
qui regarderont
Autres personnes travaillant sur les lieux. Veillez a ce
que toutes les personnes portent les lunettes de protec
tion.
or
Ia soudure, assurez-vous
Avant dattaquer
rebords dØcran ou les portes soient fermØs.
que
les
Toxic Fume Prevention
B.
Prevention des gaz toxiques
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C.
Fire and
Comply
with
Suivez les precautions du paragraphe 1.2B. LØchappe
ment du moteur de Ia generatrice doit Œtre ventilØ a lair
extØrieur. Loxyde de carbone peut tuer.
Explosion Prevention
precautions
C.
Prevention des incendies et des explosions
in 1-2C.
rated capacity. Do not overload arc
Equipments
welding equipment. It may overheat cables and cause a
Suivez les precautions 1.2C. Puissance nominale de
lappareil. Ne surchargez pas le poste de soudage a
larc. Cela peut surchauffer les cables et causer un in
cendie.
fire.
Loose cable connections may overheat
cause a fire.
Never strike
an
arc
on
vessel, It creates a brittle
rupture or lead to such
a
cylinder
area
a
that
or
can
or
flash and
other pressure
cause a violent
rupture later under rough
Les branchements lches
faire des Øtincelles et
ou
de cØble peuvent surchauffer
incendie.
causer un
Namorcez
jamais un arc sur une bouteille ou autre rØci
pression. Cela crØerait un point de rupture
entraInant a plus cu moms tongue ØchØance Iexplosion
pient
sous
du reservoir.
handling.
D.
Compressed Gas Equipment
Comply with precautions in 1-2D.
E.
Shock Prevention
Exposed hot conductors or other bare metal in the
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 surface when welding,
without suitable protection.
OM-267 Page 8
D.
Gaz comprimØ
Suivez les precautions 1.2D.
E.
Prevention des
dØcharges Ølectriques
Des conducteurs charges ou metal flu incorporØs au cir
cuit de soudage ou a un appareil chargØ sans mise a Ia
terre peuvent donner une decharge fatale a Ia personne
dorit le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans protec
tion appropriØe.
To protect
against shock:
Keep body and clothing dry. Never work in damp area
against electrical shock.
Stay on a dry duckboard, or rubber mat when damp
without adequate insulation
sweat can not be avoided.
Sweat, sea water, or
electrically HOT
or grounded metal
reduces the body surface
part
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
ness or
moisture
between
and
body
-
an
-
Pour vous protØger contre les decharges Ølectriques,
maintenez votre corps et vŒtements secs. Ne travaillez
jamais dans un endroit humide sans isolation adequate
contre les dØcharges electriques. Lorsque vous ne
pouvez Øviter lhumiditØ ou Ia sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
leau de mer, ou lhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal a Ia masse, rØduisent
Ia rØsistance electrique de Ia surface du corps, permet
tant lentrØe de courants dangereux, voire mortels.
1.
1.
When
Grounding
the
Mise a Ia terre de
welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
arc
Lorsque lappareil de soudage a larc
When
installing, connect the frames of each unit such
as welding power source,
control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
quid such as oil or fuel.
-
welding, check ground for continuity. Be sure
are
touching bare metal of equipment
conductors
frames at connections.
If
a
line cord with
a
ground
lead is
provided
with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a threeprong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2.
Electrode Holders
et
un
sont
metal avant davoir
3.
be used. Do
mis le poste de soudure a larrŒt.
A linstallation, branchez les chassis de chaque ØlØment
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sØcuritØ. Lappareil chargØ
par les courants vagabonds peut donner une decharge
risquant dŒtre mortelle. NE BRANCHEZ PAS VOTRE
PRISE DE TERRE a une conduite electrique, ou a
tuyau de gaz ou de liquide inflammable tel que lhuile
un
ou
combustible.
Connexion
triphasØe.
Avant
Iinstallation
vØrifiez
Ia
phase nØcessaire a Iappareil. Si seul le triphasØ est
disponible, ne branchez lappareil monophasØ qu deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur de terre de Iappareil au troisiŁme fil (sous
tension), autrement Iappareil serait chargØ: condition
dangereuse pouvant donner une decharge fatale.
Avant Ie soudage, vØrifiez si Ia prise de terre est
uniforme. En branchant, assurez-vous que les con
ducteurs touchent le metal nu du chassis de lappareil.
Lorsquun
appareil dolt Œtre alimentØ a partir dun
fret dalimentation,
a celui-ci.
cof
le conducteur de terre doit Œtre reliØ
Si vous avez en plus une fiche a trois broches pour Ia
Ia broche
terre, ne branchez le conducteur de terre qu
de terre. Si Ie cordon dalimentation a une fiche a trois
broches, reliez-Ie a une prise femelle tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
2.
Fully insulated electrode holders should
NOT use holders with protruding screws.
mise a Ia terre
norme
objet conducteur. Certaines de ces ob
jets
par exemple (mais pas seulement), des
bªtiments, des outils Ølectriques, des Øtablis, des
chassis de postes de soudure, des piŁces douvrage,
etc. Ne jamais touchez lØlectrode ou des objets en
IØlectrode
un
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT
a dangerous condi
tion that can shock, possibly fatally.
est
National Electrical Code, et Ia masse
est mise a Ia terre suivant Ia norme ANSI Z49.1 Safety
in Welding and Cutting, une tension peut exister entre
suivant Ia
off.
Before
lappareil
Equipment
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pince-Ølectrodes avec vis saillantes.
Connectors
3.
Fully insulated lock-type
Connecteurs
connectors should be used to
join welding cable lengths.
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler de longs cables.
OM-267
Page
9
4.
Cables
4.
Frequently inspect cables
for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
lethal shock
or damaged insulation to avoid possibly
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
-
Keep cable dry, free of oil arCd grease, and protected
sparks.
from hot metal and
5.
Terminals And Other Exposed Parts.
6.
VØrifiez frequemment lusure, les fissures et laltØration
des cables. REM PLACEZ IMMEDIATEMENT ceux dont
lisolation serait trop usØe ou altØrØe pour prØvenir les
decharges mortelles provoquØes par un cØble dØnudØ.
Vous pouvez enrouler les parties endommagØes de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez les cables secs,
dØpourvus dhuile et de graisse et mettez-les a Iabri du
metal chaud et des Øtincelles.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
TŒtes de cables et autres parties dØnudØes
Avant Ia mise
en marche, les tŒtes de cables et autres
parties dØnudØes dun appareil Ølectrique doivent Œtre
munies de leurs couvrefils isolants.
Electrode
6.
a.
Cables
Electrode
Equipment with output on/off control (con
tactor)
equipØ dune
che/arrŒt (contacteur)
Welding
power
sources
for
use
En
arc
source
b.
avec electrode fusible (GMAW), ou
electrode tungstene (GTAW) et des
procŁs semblables sont ØquipØs dune corn
mande marche/arrŒt de Ia puissance de sor
est en position
tie. Lorsque Iinterrupteur
MARCHE
et linterrupteur du pistolet est
fermØ, le fil dØlectrode devient chargØ. Ne
touchez jamais le f ii electrode ou tout autre
objet conducteur faisant contact avec le cir
cuit dØlectrode sans couper le courant au
paste de soudure.
avec
is off.
Equipment without output on/off control
b
(no contactor)
Welding
metal
power
Appareil non-ØquipØ dune
.
sources
used with shielded
7.
touch
power
the
electrode
source
unless
the
is off.
Safety Devices
7.
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation,
inspection,
ment, shut OFF all power and
or
service,
of
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
shut OFF and
Power disconnect switch must be available
power
OM-267 Page 10
source.
de sØcuritØ
Le dispositif de securite-verrouillage et coupe-circuit
doit pas Œtre dØbranchØ ou dØshuntØ.
Avant
ne
linstallation, linspection
near
the
ou
Ia
reparation
de
lap
lalimentation sur ARRET et enlevez les
fusibles gØnØraux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez taus les cØbles de Ia source de courant ainsi que fes
prises des cordons dalimentation en 115 volts.
pareil,
mettez
et ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia palaritØ. Sil est dØbranchØ au
cours
dune
Lors du
decharge
disconnect all power to
welding
Dispositif
equip
line fuses (or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
remove
Leaving equipment unattended. Always
equipment.
pastes
soudage a
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never
mar
de soudure utilisØs pour le
electrode enrabØe
arc
avec
(SMAW) et des procŁs semblabes peuvent
commande mar
Łtre non-ØquipCs dune
che/arrŒt de Ia puissance de sortie. Lorsque
linterrupteur est en position ~MARCHE
Ne touchez
electrode
devient chargØ.
jamais lØlectrode sans couper le caurant au
poste de soudure.
Les
welding (SMAW) and similar pro
may not be equipped with welding
welding
commande
che/arrŒt (sans contacteur)
arc
cesses
gØnØral, les pastes de soudure utilisØs
soudage a larc sous protection
pour le
gazeuse
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power
mar
with the gas
welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per
mit on-off control of the welding power out
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
metal
commande
Appareil
a.
urgence, faites attention aux brQlures de
jaillissernents dØtincelles.
ou aux
Appareil laissØ sans surveillance. Mettez
ARRET et dØbranchez lappareil.
toujours
sur
F.
Protection For Wearers Of Electronic Life
Linterrupteur
Support Devices (Pacemakers)
imitØ de Ia
Magnetic
fields
from
high
currents
can
affect
F.
-
revisions and comply
1.
as
applicable:
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
2.
coeur)
Inducteurs de courant ØlevØ peuvent nuire le fonction
nement dun
appareil pour Ie reglement de battement
de coeur.
Toute personne portant un appareil Ølec
tronique de sauvetage (appareil pour le rŁglement de
battement de coeur), devrait consulter un docteur avant
dapprocher toute operation de soudage a larc, a Ia
gouge
1-4.
5.
6.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
obtainable from the
FACE PROTECTION
American National Standards Institute, 1430
Broadway, New York, NY 10018.
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
AWS Standard A6.0, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd., P.O. Box
351040, Miami, FL 33135.
8.
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
NFPA
10.
INDEX
DES
NORMES
-
Pour
aux normes
plus de
de IACNOR
amØricaines suivantes:
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par lAmerican Welding
Society, 550 Le Jeune Rd., P.O. Box 351040
Miami, FL 33135
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, distribuØ par U.S. Department of
Labor, Washington D.C. 20210
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY
TOE FOOTWEAR distribuØ par Iad
dresse donnee en 4.
-
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par laddresse donnee en 4.
7.
AWS Standard A6.O, WELDING AND CUT
HAVE COM
TING CONTAINERS WHICH
BUSTIBLES distribuØ par Iaddresse donnee en
8.
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING
distribuØ par Ia National Fire Protection Associa
tion, 470 Atlantic Avenue, Boston, MA 02210
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE distribuØ par laddresse donnØe
-
02210.
9.
point.
1.
NY 10018.
7.
a
ou aux normes
Documents, U.S. Government Printing Office,
4.
ou
NIOSH,
Washington, D.C. 20402.
3.
trouver a prox
appareils electroniques de sauvetage (ap
pareil pour le rŁglement de battement de
renseignements, rØfØrez-vous
HEALTH IN ARC
SAFETY AND
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
se
Protection pour toute personne portant des
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going near arc welding, gouging, or
spot welding operations.
For more in
1-4. STANDARDS BOOKLET INDEX
formation, refer to the following standards or their latest
darrŒt doit toujours
de courant.
source
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA
en
10.
-
8
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
8
OM-267 Page 11
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS distribuØ par
Ia Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
12.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
Rexdale
178
Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
13.
SAFETY
WELDING
NWSA
booklet,
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
13.
SAFETY
WELDING
NWSA
booklet,
National
Ia
distribuØ
BIBLIOGRAPHY
par
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
Welding Society Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding Society,
550 Le Jeune Rd., P.O. Box 351040, Miami, FL
14.
American Welding Societe Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
distribuØ par American Welding Societe, 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33135
33135.
15.
ANSI Standard Z88.2 Practice For Respiratory
National
distribuΠpar IAmerican
Protection
Standards Institute, 1430 Broadway, New York,
NY 10018.
Philadelphia, PA 19103.
14.
15.
American
ANSI Standard Z88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
OM-267 Page 12
SECTION 2- INTRODUCTION
Specifications
Table 2-1.
At Rated
Load Output
60 Hz Three-Phase
Input
Max.
Rated
Model
Welding
Output At 100%
Duty Cycle
Open-
Amperes
Circuit
Voltage
At
Weight
230V
460V
575V
kva
kw
1000
1000 Amperes
At 76 Volts DC
85
224
112
90
89
~,5
1500
1500 Amperes
At 76 Volts DC
85
330
165
132
131
12~
Net
Ship
896 lbs.
986 lbs.
(406 kg)
(447 kg)
1068 lbs.
1158 lbs.
(484 kg)
(525 kg)
1-7/8 In.
(47.6 mm)
TB~079 823
*Dumenslon Includes 2-7/8 In.
(73 mm) Lifting Eye
Figure
2-1. Overall Dimensions And Base
Mounting Hole Layout
~00
90
80
70
~
0
>
60
50
U
~
40
30
20
10
0
200
400
600
800
DC AMPERES
1000
1200
1400
1600
B-047 999
OM-267 Page 13
Chart 2-2.
nameplate of this unit uses international symbols
labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
The
Duty Cycle
for
RATED
OUTPUT
2000
MODEL
B.
Safety
__
~%
GPS-1500
1500
In
__
w
w
~%
4
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be
installed, operated, and maintained only by qualified
persons in accordance with this manual and all applica
ble codes such as, but not limited to, those listed at the
end of Section 1
Safety Rules For Operation Of Arc
Welding Power Source.
-
GPS1000
1000
E
C,
z
900
w
instructions specifically pertaining to this unit
appear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
Safety
~1
800
GPS-750
700
600
different levels of hazard.
~__ =
WARNING statements include installation, operation,
and maintenance
500
GPS-500
40
50
60
70
80
carefully
or
90 100
% DUTY CYCLE
procedures
or
practices which if not
personal injury
followed could result in serious
loss of life.
CAUTION statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury or
damage
to this
equipment.
B-079 809
signal word, IMPORTANT highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
A third
tions which need
VOLT-AMPERE CURVE (Chart 2-1)
2-1.
The
volt-ampere curve shows the voltage and amper
age output capabilities of the welding power source. Re
ferto the volt-ampere curve (Chart 2-1) to determine the
weld amperage at a particular load voltage.
2-2.
DUTY CYCLE
(Chart 2-2)
The
duty cycle is the percentage of a ten minute period
welding power source can be operated at a given
output without overheating and damaging the unit. This
welding power source is rated at 100 percent duty cycle;
therefore, the unit can be operated at rated load continu
that
a
ously.
Refer to the
Duty Cycle Chart (Chart 2-2) to determine
welding power source at various duty
cycles.
4A
CAUTION: EXCEEDING DUTY CYCLE RAT
ING will damage unit.
Do not exceed indicated
A.
duty cycle(s).
GENERAL INFORMATION AND SAFETY
General
Information
presented
in this manual and
on
various
RECEIVING-HANDLING
Before unpacking equipment, check carton for any dam
age that may have occurred dunng shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufactur
ers
Transportation Department.
When
requesting information about this equipment,
always provide Model Description and Serial Number.
2-5.
the output of the
2-3.
2-4.
DESCRIPTION
This unit is
three-phase, dc, dual-polarity welding
provides constant voltage (CV) out
put to Multiple Operator Grids. The unit is primarily used
for Shielded Metal Arc Welding (SMAW), Gas Tungsten
Arc Welding (GTAW), and Air Carbon Arc Gouging.
a
power source which
GPS power sources have a maximum open-circuit volt
age (ocv) of 85 volts. They supply rated output at 76
volts full load and provide 150% of rated output for two
minutes after operating at full rated load. These power
sources can be paralleled to supply welding current
when needed for large quantities of grids.
labels, tags, and plates on the unit pertain to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
IMPORTANT: A Field Installation Kit may be necessary
when paralleling GPS- 1500 models manufactured be
fore 1981. Contact the manufacturer before paralleling
followed for the safe and effective
these units.
OM-267
Page
14
use
of this
equipment.
SECTION 3
3-1.
UNIT INSTALLATION AND RELOCATION
welding power source has a lifting eye for lifting or
moving the unit, and the base contains prepunched
mounting holes. (See Figure 2-1 for base mounting hole
layout.) The unit has space underneath it if lift fo~i~s are
This
LOCATION
a
WARNING:
FALLING EQUIPMENT can
cause serious personal injury and equip
damage.
Use lifting eye
ment
to be used for
only, NOT running
her
of
heavy accesso
gear, gas cylinders, orany
to lift unit
procedures.
to lift
capacity
it.
The location should allow room to remove the top cover
and side panels for installation, maintenance, and repair
ries.
Use equipment of adequate
the unit.
moving
The service life and
efficiency of this unit are reduced
subjected to high levels of dust, dirt, moisture,
when it is
If using lift forks to handle this unit, be sure the
lift forks are long enough to extend out of the
opposite side of the base.
corrosive vapors, and extreme heat.
3-2.
WELD OUTPUT CONNECTIONS
lift forks too short will expose internal
components to damage should the tips of the lift
forks penetrate the bottom of the unit.
Using
RATED OUTPUT
To obtain full rated
RESTRICTED AIRFLOW causes overheating
and possible damage to Internal parts.
Maintain at least 18 inches (457 mm) of unre
stricted space on all sides of unit, and keep un
derside free of obstructions.
affected.
Do not place any filtering device over the in
take air passages of this welding power source.
Warranty is void
if any
output from this unit, select, prepare,
and install proper weld cables. If any of these areas are
neglected, the welding performance of the unit may be
A.
Weld Cable Selection
1.
Keep cables as short as possible, and place cables
together. Excessive cable length adds resis
tance which may reduce output or cause the unit to
close
type of filtering device is
used.
overload.
Table 3-1. Weld Cable Size
Total Cable
Weldin
~
(Copper) Length
in Weld Circuit Not
Exceeding*
50 ft. Or Less
100 ft.
150 ft.
200 ft.
250 ft.
300 ft.
350 ft.
(15 m)
(30 rn)
(45 m)
(60 m)
(70 m)
(90 m)
(105 m)
10 Thru 100%
400 ft.
(120 m)
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
2
2
1
1/0
2/0
3/0
4/0
4/0
250
1
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
2/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
2/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
4/0
4/0
4/0
2-2/0
2-3/0
2-4/0
1000
1000
2-750
600
4/0
4/0
2-2/0
2-3/0
2-4/0
1000
1000
700
4/0
2-2/0
2-3/0
2-4/0
1000
1000
2-750
2-750
800
2-2/0
2-2/0
2-3/0
2-4/0
1000
2-750
2-750
2-1000
900
2-3/0
2-3/0
2-4/0
1000
1000
2-750
2-1000
2-1000
1000
2-3/0
2-3/0
2-4/0
1000
2-750
2-750
2-1000
2-1000
1250
2-4/0
2-4/0
750
2-750
2-750
2-1000
2-1 000
1500
500
750
1000
2-750
2-1 000
2-1 000
1750
750
1000
2-750
2-1000
2-1000
*Weld cable size (AWG and
circular mils per ampere.
MCM)
is based
on
either
a
4 volts or less
drop
or a
current
density
of more than 300
S.0008/8.88
OM-267
Page
15
2.
C.
Use weld cables with an insulation voltage rating
equal to or greater than the maximum open-circuit
voltage (ocv) of the welding power source (see
Table 2-1).
Weld Cable ConnectIons
Do not connect weld terminals
bars are installed.
if bus bars are not removed and output terminals
connected together, the unit is short-
are
circuited.
(Figure 3-1)
welding power sources have two positive weld
output terminals (Positive A and Positive B) and two
negative output termi nals (Negative A and Negative B).
The weld output terminals are located behind the
access door on the lower portion of the front panel.
Consult all applicable safety
installing weld cables.
These
To make weld cable connections,
4A
proceed
as
together if bus
follows:
WARNING: ELECTRIC SHOCK can kill;TWO
TIMES NORMAL OUTPUT VOLTAGE can re
sult from certain connections.
Do not touch live electrical parts.
welding power source, and dis
input power employing lockout/tagging
procedures before inspecting or installing.
Shut down
connect
of
consist
procedures
Lockout/tagging
in
switch
line
disconnect
posi
open
padlocking
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
Connect weld cables only to matching output
terminals (Positive A and Negative A or Positive
B and Negative B) unless bus bars are installed.
output terminal is connected to
B
Negative output terminal and the bus bars
are not installed, twice the normal output voltage
will be present between terminals Negative A
and Positive B. The same is true if Negative A
If the Positive A
IMPORTANT:
codes before
Make weld cable connections for the
welding polarity required electrode negative/straight
polarity (DCSP) or electrode positive/reverse polarity
(DCRP).
1.
If
1000
the
Ampere
Models
output terminals
are
bused
together (see
Figure 3-1), 1000 amperes of weld current is available
between the positive and negative output terminals.
output terminals are not bused together, 500 am
of
weld current is available between Positive A
peres
and Negative A terminals, and 500 amperes otcurrentis
If weld
available between Positive B and
Negative
B terminals.
These welding power sources
IMPORTANT:
shipped with bus bars installed (see Figure 3-1).
2.
If
1500
the
Ampere
are
Models
output terminals
are
bused
together (see
Figure 3-1), 1500 amperes of weld current is available
between the positive and negative output terminals.
the
output terminal is connected to Positive B output
terminal twice the normal output voltage will be
present between Positive A and Negative B.
OM-267
Page
16
If weld
output terminals
are
not bused
together, 500
am
peres of weld current is available between Positive A
and Negative A terminals, and 1000 amperes of current
is available between Positive B and
Negative
B termi
nals.
IMPORTANT:
These welding power sources
shipped with bus bars installed (see Figure 3-1).
are
Positive
Terminals
Negative
Terminals
'
'
~ J\Bus
Bus
Bar
Bar
1000 Amps Available Between
Positive and Negative Terminals
500 Amps Avallable.a#
Between Positive A
And Negative A
IMPORTANT:
500 Amps Available
Between Positive B
And Negative B
1000
and twice (he
available
between
output voltage
Positive A and Negative B OR between
Negative A and Positive B terminals if bus
bars not installed.
normal
Amps
arc
1000 AMPERE MODELS
Positive
Terminals
Positive
Terminals
Negative
Terminals
Negative
Terminals
@
J~j
A
B
@
Bus
Bar
A
Bus
Bar
B
1500 Amps Available Between
Positive and Negative Terminals
1000 Amps Available
Between Positive B
And Negative B
500 Amps Available
Between Positive A
And Negative A
IMPORTANT:
1500 Amps and twice the
voltage arc available between
and Negative B OR between
normal output
Positive A
Negative
A and Positive B terminals if bus
bars not installed.
1500 AMPERE MODELS
S-0041
Figure
3-3.
ELECTRICAL
(Figure
3-2 And
INPUT
3-1. Weld
CONNECTIONS
Figure 3-3)
INPUT
A.
Electrical
Operate
the
Input Requirements
welding power source from a three-phase,
60 Hz, ac power supply. The input voltage must match
one of the electrical input voltages shown on the input
data label on the unit nameplate. Contact the local elec
tric utility for information about the type of electrical
service available and how properconnections should be
Output Connections
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Shut down welding power source, and dis
input power employing lockout/tagging
procedures before inspecting or installing.
connect
consist
of
procedures
Lockout/tagging
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other
disconnecting device.
made.
OM-267 Page 17
Jumper Link Placement (Multi-Voltage
Only) (FIgure 3-2)
B.
Models
IMPORTANT:
Single-voltage models (except
GPS- 1500 V models) are wired directly to the contactor
they do not have an input terminal board.
IMPORTANT: All directions, such as left or right, are
with respect to the operator facing the unit front panel.
These units are equipped with input voltage jumper links
installed onto the input terminal board. The position of
the jumper links determines at which line voltage the
welding power source will operate. Both models, 1000
Ampere and 1500 Ampere, are shipped with links posi
tioned forthe highest voltage stated on the nameplate. If
the unit is to be operated from a lower input voltage, re
move right side panel and reposition jumper links to
match the available line voltage (see input voltage label
on or near input terminal board). Proceed as follows:
right side panel.
1.
Remove
2.
Compare position of jumper links on the input termi
nal board to the voltage link arrangement shown on
input voltage label.
4A
Jumper Link Placement For Input Voltage Corn
pensatlon (GPS-1500V Models Only) (FIgure 3-3)
C.
These power sources are able to compensate for high or
low incoming line voltage. The level of compensation is
determined by jumper link placement on the input
terminal board. The input terminal board has three
terminals which represent three levels of voltage
compensation: +5%, 0%, and -5%. Position jumper
links
follows:
as
IMPORTANT: The unit is shipped with the jumper links
positioned for 0% (zero) compensation; therefore, if the
incoming line voltage is relatively close to the input
requirement, do not change jumper link position.
1.
If the
incoming line voltage is high, position jumper
compensation.
links for +5%
2.
voltage is low, position jumper
compensation.
If the line
-5%
links for
IMPORTANT: All three jumper links must be positioned
for the same percentage of compensation (see
Figure 3-3).
ic~~ic~
II
II
II
L~~LoJ
INCORRECT INPUT VOLTAGE
CAUTION:
JUMPER LINK PLACEMENT can damage
unit.
II
Position jumper links as shown on the input
voltage label located on the input terminalboard
or the center upright inside the welding power
II
II
L~~LJ
source.
II
Store unused
terminals.
jumper
links
across
linked
+5%
3.
jumper links onto the input terminal board
to match the available input line voltage.
4.
Reinstall
Reinstall
right
side
panel.
Line Terminals
II
0%
5%
S-0042
FIgure 3-3. Jumper LInk Position For Voltage
Compensation (GPS-1500V Models Only)
D.
2-5/8 in. (66.7 mm)
Dia. Access Hole
II
Lc~~LoJ
Input Conductor ConnectIons (FIgure 3-2)
a
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Install a fusible line disconnect switch in the
circuit to the welding power source.
input
The input circuit switch provides a safe and con
venient means to completely remove all electri
cal
powerfrom the welding power source when
it is necessary to inspect or service the unit.
ever
Employ lockout/tagging procedures on input
making input connections to the
welding power source.
line before
of
consist
procedures
Lockout/tagging
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other
disconnecting device.
Input Voltage Jumper Links
1000 Model Illustrated
3-2. LocatIon For
TA-079 825-A
Input Conductor
Connections (1000 Ampere Model Shown)
FIgure
OM-267
Page
18
Connect input conductors to the welding
power source before connecting to three-phase
input power.
WARNING: ELECTRIC SHOCK
Table 3-2. Input Conductor And Fuse Size
Conductor
Size
Ground
Conductor
Size
Fuse
Size in
(AWG)
(AWG)
Amperes
Input
Model
1000
Ampere
input
Voltage
230V
4/0
3
350
460V
2
6
175
575V
2
6
125
230V
400MCM
2
500
460V
2/0
4
250
575V
1/0
4
225
Do not connect an input conductor to the
in the unit.
Do not connect the
line terminal.
(NEC) specifications
ground
conductor to
an
input
input connections can result in an elec
energized welding power source
chassis. The ground terminal is connected to
the welding power source chassis and is for
grounding purposes only.
Incorrect
trically
National Electrical Code
for allowable ampacities of insulated
*Conductor size is based
kill.
ground terminal
1500
Ampere
can
on
5.
copper conductors, having a temperature rating of 167F
(75C), with not more than three single current-carrying
conductors in a raceway (Article 310 of NEC). (The ground
conductor is not counted as a current-carrying conductor.)
6.
Obtain and install
into the rear panel
a
standard conduit strain relief
access
insert the
conductors
installed in
Step
hole.
through
the
strain
relief
5. Route conductors to the
input
terminal board.
*Fuse size is based on not more than 200 percent of the
rated input amperage of the welding power source (Article
630 of
NEC).
s-co
7.
8.
1.
2.
Table 3-2 as a guide, select and obtain line
fuses for the disconnect switch.
Using
Using Table
guide, select input conductors
for the installation. The input conductors should be
covered with an insulating material that complies
3-2 as
a
9.
4.
Install terminal lugs of adequate amperage capacity
and correct stud size onto input and ground
conductors.
Remove left side
conductors to the line terminals
input
the contactor.
Connect the
ground
nal located
on
source near
the contactor.
conductor to the ground termi
the frame of the welding power
Connectthe
remaining end of the ground conductor
ground. Use a grounding method that
complies with applicable electrical codes.
to a suitable
with national, state, and local electrical codes.
3.
Connect the
on
rn-se
10. Connect
remaining ends of input conductor
deenergized line disconnect switch.
11. Secure the
input
cable in the strain relief.
12. Reinstall left side
panel.
to a
panel.
SECTION 4- OPERATOR CONTROLS
Pilot Light
Circuit Breaker
(See
Start
And
Stop
Push Buttons
Section 6-3)
Ammeter
Voltmeter
Ammeter
Bus Bar
Bus Bar
A
Positive B
Output
Output Terminal
Terminal
TB-079 824
Figure
4-1.
Operator Controls
OM-267
Page
19
4-1.
START AND STOP PUSH-BUTFON SWITCH
4-2.
PILOT LIGHT (Figure 4-1)
(Figure 4-1)
pilot light comes on when
pressed, indicating that the unit
The
~
POWER
CONTROL
4-3.
I
METERS
The meters
ON
energized.
are
provided
are
to monitor the
welding opera
not intended for exact current or
measurements. The meters are
internally
con
nected to the output circuit. The voltmeters indicate the
voltage at the weld output terminals, but not necessarily
OFF
push button energizes the welding
power source, placing it in a ready-to-weld status. Depressing the Stop push button shuts down the unit,
Depressing the
is
(Figure 4-1)
tion; however, they
voltage
the Start button is de
Start
voltage at the welding arc (due to cable resis
tance, possible poor connections, etc.). The ammeters
indicate the current output of the unit.
the actual
SECTION 5- SEQUENCE OF OPERATION
a
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious Injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
can
Wearers should consult their doctor before
going near arc
Do not touch live electrical parts.
Keep all
operating.
and
covers
panels
in
place
See Section 1
while
-
Safety
removed.
5-1.
ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and skIn; NOISE can damage
1.
can
FUMES AND GASES
your health.
can
body protection.
seriously
2.
keep
from
harm
fumes and
breathing
Install and connect
welding power
source as
in-
Install and connect auxiliary
Manual.
equipment according to
its Owners
3.
Energize welding power
equipment.
4.
Begin operation.
head out of the fumes.
Ventilate to
UNIT PREPARATION FOR OPERATION
structed in Section 3.
hearing.
Wear correct eye, ear~ and
Rules For Operation Of
for basic welding
Welding Power Source
safety information.
Arc
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
Keep your
welding, gouging, orspot welding
operations.
source
and
auxiliary
gases.
If ventilation is
breathing device.
inadequate,
use
approved
52.
1.
HOT METAL, SPATTER, AND
cause fire and burns.
SLAG
SHUTTING DOWN
Stop welding.
can
2.
Deenergize
the
STOP
Watch for fire.
all auxiliary equipment, and depress
push button on the welding power
source.
fire
how to use it.
Keep
a
extinguisher nearby,
and know
3.
Do not use near flammable material.
Allow work and
handling.
OM-267
Page
20
equipment
to cool before
Turn off the
shielding gas supply,
if
applicable.
WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in
use.
MAINTENANCE & TROUBLESHOOTING
SECTION 6
ROUTINE MAINTENANCE
6-1.
a
Do not touch live electrical parts.
Shut down
welding power
source, and dis
input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
connect
Lockout/tagging procedures
locking line disconnect switch
FAN MOTOR
6-2.
WARNING: ELECTRIC SHOCK can kill.
consist of pad
in open position,
These units are equipped with an exhaust fan and relies
on forced draft for adequate cooling. The fan motor is
manufactured with lifetime sealed bearings and re
quires
no
OVERLOAD PROTECTION
6-3.
4A
removing fuses from fuse box, or shutting off
red-tagging circuit breaker or other discon
necting device.
can cause
serious
Allow
can cause severe
to be
servicing.
Injury.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
necting device.
burns.
performed only by qualified per-
Sons.
A.
Table 6-1. Maintenance Schedule
Month
Units in
heavy service
Fuse Fl
4A
MAINTENANCE
FREQUENCY
Every
kill.
input power employing lockout/tagging
procedures before inspecting, maintaining, or
cooling period before servicing.
Troubleshooting
can
Do not touch live electrical parts.
connect
Keep away from moving parts.
HOT SURFACES
WARNING: ELECTRIC SHOCK
Shut down welding power source, and dis
and
MOVING PARTS
maintenance.
WARNING: Read and follow safety Informa
tion at beginning of entire SectIon 6 before
proceeding.
environ
Check weld cables and
clean
internal
labels;
parts
(see Section 6-1 B).
ment:
Fuse Fl is
from
a cartridge-type fuse which protects the unit
damage due to an internal short or excessive over
load in control transformer T2. If Fl opens, the unit be
completely inoperative. If Fl opens, locate and
correct the problem, and replace Fl as follows. If Fl
opens repeatedly, contact the nearest Factory Author
ized Service Station.
comes
Every
3 Months
Check weld cables (see Section
6-iA).
Every
6 Months
Check all labels (see
IMPORTANT at beginning
of
Section 6-1).
Clean internal parts
Yearly
Remove left side
2.
Locate fuse Fl on center
Figure B), and remove Fl.
3.
Install
(see Section
6-1B).
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
A.
1.
Weld Cables
Every three months inspect cables for breaks in insula
Repair or replace cables if insulation breaks are
present. Clean and tighten connections at each in
spection.
a
new
panel.
panel (see
Parts List
fuse Fl, and reinstall left side
CAUTION:
IMPROPER FUSES
can
panel.
damage
this unIt.
If replacement becomes necessary, use only
fuses of the proper size, type, and rating (see
Parts List).
B.
Circuit Breaker CB
(Figure 4-1)
tion.
B.
Internal
CleanIng
Every year blow out or vacuum dust and dirt from the in
ternal components of the welding power source. Re
the outer enclosure from the unit, and use a clean,
dry airstream or vacuum suction for the cleaning opera
tion. if dirty or dusty conditions are present, clean the
move
unit more
frequently.
OVERLOAD
a
WARNING: Read and follow safety Informa
tion at beginning of entIre Section 6 before
proceeding.
Circuit breaker CB protects the unit if the secondary
main transformer Ti is drawing an excessive
amount of current. Current transformers CT1 and CT2
sense the current in the secondary of Ti. If CT1 and CT2
sense that the secondary is drawing too much current,
winding of
OM-267
Page
21
removing fuses from fuse box, or shutting off
red-tagging circuit breaker or other discon
necting device.
circuit breaker CB opens, the contactor is deenergized,
and the unit shuts down. Locate and correct the prob
lem, and manually reset the circuit breaker.
THERMAL PROTECTION
6-4.
and
MOVING PARTS
(THERMOSTAT TP1)
Keep away
Thermostat TP1, located in the main transformer Ti, is
wired into the contactor W circuit. If the unit overheats,
TP1 opens, contactor W is dropped from the circuit, and
the unit shuts down. If TP1 opens, let unit cool before
can cause
from
HOT SURFACES
Allow
injury.
moving parts.
can cause severe
cooling period
Troubleshooting
resuming operation.
serious
before
burns.
servicing.
performed only by quali
to be
fied persons.
TROUBLESHOOTING
6-5.
The
a
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis
input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
consist of
pad
position,
in open
is
designed to diagnose
and
provide
develop in
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these proce
dures, contact the nearest Factory Authorized Service
Station. In all cases of equipment malfunction, strictly
follow the manufacturers procedures and instructions.
connect
Lockout/tagging procedures
locking line disconnect switch
following chart
remedies for some of the troubles that may
these welding power sources.
Chart 6-1. TroubleshootIng
No
Line disconnect switch in OFF
output.
REMEDY
PROBABLE CAUSE
TROUBLE
position.
Place line disconnect switch in ON
position.
Check and
Line fuses.
replace
line fuses, if
necessary.
(see Section 6-3).
Fl
Fuse Fl.
Replace
Circuit breaker C.
Reset CB
(see Section 6-3).
Replace_CB.
Let unit cool before
Section 6-4).
Thermostat TP1.
Replace
Input voltage jumper links not in proper
position on primary terminal board TEl.
Improper
electrical
input connections.
Start and
Stop push-button
Input voltage jumper links
position.
No weld output; Ian
Improper
operative,
terminals.
Low
or
high output.
switch PB1.
not in proper
connections to weld output
operating (see
TP1.
See Section 3-3 for proper
link
jumper
position.
See Section 3-3 for proper
connections.
Be sure that Start
been depressed.
input
push button
See Section 3-3 for proper
link position.
has
jumper
See Section 3-2 for proper weld
output connections.
Input voltage jumper
position.
links not in proper
link
position.
Erratic weld output.
Loose
Fan motor FM inoperative
and/or overheating,
Fan blade obstruction.
Remove obstruction and check fan
blade. Replace FM, if necessary.
Fan motor FM.
Check and
OM-267
Page
22
or
dirty
weld cable connections.
See Section 3-3 for proper jumper
Clean and tighten all weld cable
connections.
replace FM,
if necessary.
SECTION 7- ELECTRICAL DIAGRAMS
Circuit
7-1. Circuit
Diagram
Diagram No. B-086
792
For GPS-1 000 Models
-
Diagram
230V
4SOV
230V
Circuit Diagram No. B-088 038-A
Diagram
7-2. Circuit
Diagram
For GPS-1500A Models
OM-267
Page
23
L
ONLy
Circuit
Diagram 7-3. CIrcuit Diagram For GPS-1500V Models
OM-267
Page
24
Diagram
No. B-008 039-A
SECTION 8- PARTS LIST
OM-267 Page 25
Figure
OM-267
Page
26
8-1
Left Side View
Replace Coils
Item
No.
Figure
T2
3
T2
4
W
4
W
004 104
Wi
Wi
Fl
Fl
SR1 ,1 1
SR1
048599
004 259
*004 258
048 731
034 821
*088 384
*012 639
070 404
079 827
079 827
037 157
Rl
031 689
085 294
VR1
035 645
SR11
045 586
031 689
037156
085 295
Ri 1
035 645
025638
059 118
VR1
9
V1,2
Al ,2
8
9
Al
9
10
A2
PB1
11
PL1
059 118
044 104
011 636
*027 629
027 631
027 628
12
CB
034 945
059 563
059 616
13
14
15
15
Model
Left Side View
3
7
Factory Authorized Service Station
Quantity
120 496
070 558
036 630
092 773
099 044
7
or
Description
8-1
1
5
6
7
Factory
Part
No.
Dia.
Mkgs.
2
5
at
Shunt
Shunt
079 388
072 425
059
601
601
059
038
602
602
16
567
841
842
566
909
249
219
038 032
*Recommended
Spare
PLATE, adapter-power cord
PANEL, rear
TRANSFORMER, control (230/460)
TRANSFORMER, 1/2 KVA (460/575)
CONTACTOR, 3P 110-120/220-240 (consisting of)
CONTACTOR, 3P 210 amp 600 volts (consisting of)
....
1000
1500A
1500V
1
1
1
1
1
1
1
1
1
1
1
1
1
1
~COlL
1
COIL
1
1
KIT, point-contact
INTERLOCK, contactor NO
INTERLOCK, contactor NO
FUSE, cartridge 1 amp 600 volts (230/460)
FUSE, cartridge 6 amp 600 volts (460/575)
HOLDER, fuse
RECTIFIER, silicon diode (consisting of)
RECTIFIER, silicon diode (consisting of)
DIODE, 275 amp 250 volts SP
1
1
12
12
12
CAPACITOR, ceramic 0.01 uf 500 volts
6
6
6
RESISTOR,
VARISTOR,
1
1
1
6
6
6
1
1
-
1
1
1
1
1
1
WW fixed 5 watt 2K ohm
8 joule 150 volts
RECTIFIER, silicon diode (consisting of)
CAPACITOR, ceramic 0.01 uf 500 volts
~DlODE,275amp250volts
RESISTOR, WW fixed 5 watt 2K ohm
VARISTOR, 8 joule 150 volts
METER,voltsdc0-lOO scale
METER, amp dc 50 MV 0-800 scale
-
...
HOUSING, light slide base 125 volts
LENS, light red clear
-
-
CIRCUIT BREAKER, manual reset 2P 5 amp 240 volts
BAFFLE, air top rectifier
BRACKET, mounting terminal board
SHUNT, meter 50 MV 800 amp
SHUNT, meter 50 MV 1500 amp
TERMINAL, power output (consisting of)
NUT, brass hex jam 5/8-11
1
1
6
6
18
18
1
6
6
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
-
-
1
1
2
-
-
1
2
.
METER, amp dc 50 MV 0-800 scale
METER, amp dc 50 MV 0-1.5K scale
SWITCH, push button start stop 60 amp 110 volts
BULB, incandescent slide base 120 volts
1
1
-
ac
1
1
1
16
8
16
16
8
8
2
2
2
STUD, brass 5/8-11 x 3
WASHER, flat SAE 5/8
WASHER, lock external tooth 5/8
8
8
8
8
8
8
8
8
8
BUS BAR
4
4
4
-
-
NUT, brass hex full 5/8-11
TERMINAL BOARD
-
-
-
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-267
Page
27
29
30
!32
Figure
OM-267
Page
28
8-2
-
Right Side
View
Item
No.
Figure
Dia.
Mkgs.
105 630
+070 556
605 583
29
TEl
059 555
29
TEl
049 957
29
TEl
044 098
038 897
038 980
602
010
*601
038
038
TE2
221
910
838
621
804
038 898
*038 620
038 602
083 640
R2
30
059 585
083 637
032 616
032 605
059 983
070 644
092 771
30
31
FM
33
34
Ti
34
34
Ti
Ti
092 772
092 786
34
Ti
092 787
34
Ti
092
092
092
092
092
092
TP1
35
Description
Left Side View
8-2
28
32
Quantity
Part
No.
788
302
303
301
300
295
092 624
080 075
CT1 ,2
+120 495
109 035
+070 555
123 154
010014
026 627
LABEL, electric shock can kill
PANEL, front
CATCH, spring-loaded door
TERMINAL, pri (230/460) (consisting of)
TERMINAL, pri (460/575) (consisting of)
TERMINAL, pri (consisting of)
TERMINAL BOARD, pu
TERMINAL BOARD, pri
WASHER, lock-internal tooth 3/8
WASHER, flat 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
BLOCK, terminal 30 amp 3 pole (460/575)
RESISTOR, grid
WINDTUNNEL, 20 inch
WINDTUNNEL, 20 inch
BLADE, fan 60 Hz 20 inch 3 wing 21 deg
MOTOR, 1/4 hp 230 volts ac 1625 rpm
-
-
BUS BAR,
BASE
jumper
-
secondary
TRANSFORMER
(230/460) (consisting of)
TRANSFORMER (460/575) (consisting of)
TRANSFORMER (230/460) (consisting of)
TRANSFORMER (460/575) (consisting of)
TRANSFORMER (460) (consisting of)
COIL, pri/sec (230/460)
COIL, pri/sec (460/575)
COIL, pri/sec (230/460)
COIL, pri/sec (460/575)
COIL, pri/sec (460)
THERMOSTAT, NC
TRANSFORMER, current 300/5
PANEL, side
LABEL, warning electric shock can kill etc
COVER, top
LABEL, general precautionary
ordering
a
1 500A
1 500V
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
9
1
1
GASKET, lifting eye-cover
component originally displaying
a
12
9
18
24
42
12
9
6
3
18
3
1
2
use
quantities
on
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
I
1
1
6
6
6
6
6
6
6
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
2
2
1
i
1
precautionary label,
18
36
CLAMP,3/4diaxi3/64mtghole
*Quantities change according to voltage. When ordering
+When
1000
6
board in unit.
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-267 Page 29