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