Download Miller Electric GPS-1000 Specifications

October 1981
FORM: OM-267C
Effective With Serial No. JB522183
MODEL
GPS-1000
G PS-i 500A
GPS-1 500V
OWN ERS
MANUAL
HilliER
~
\.~
MILLER ELECTRIC MFG. CO.
718 5. BOUNDS ST. P.O. Box 1079
APPLETON
WI
54912 USA
ADDITIONAL COPY PRICE 55 CENTS
NWSA CODE NO. 4579
PRINTED
IN
U.S.A.
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LIMITED
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
LIMITED
(
cessories
(
~
WARRANTY-Subject
to the terms and
conditions
As
hereof, Miller Electric Mt g. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade acor
other
items
manufactured
trade accessories and other items
engines,
by
are
subject
the warranties of their
respective manufacturers, if
by their manufacturer for one
of original purchase.
engines
date
are
any
warranted
or any other duty
of any goods, the exclusive remedies
therefore shall be, at Millers option Ill repair or 121 replacement
In the
d
~
Miller in appropriate cases, 131
replacement at an authorized
Miller service station or 141 payment of or credit for the purchase
price Iless reasonable depreciation based upon actual usel upon
risk and expense. Upon receipt
return of the goods at Customers
of nOtice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
All
.
year from
specified below, Millers warranty does not apply
to components having normal useful life of less than one Ill
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship, or material.
ranted
Equipment
required
to honor
warranty claims
in the event of failure resulting from
within the
ment to
following periods
the original user:
from the date of
on
a
breach of warranty
quality
the reasonable cost of
as
Miller shall be
of Millers
case
or, where authorized in
to
,
Except
geiteral policy only, Miller may honor claims
original user within the foregoing periods.
with respect to the
Such
others.
sold
matter of
a
submitted by the
f
writing by
repair
or
?
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
GUARANTY OR REPRESENTA-
IMPLIED WARRANTY,
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
TION
war
defect
ANY
delivery of Equip-
TO
AS
IMPLIED WARRANTY OF MERCHANTABILITY OR
,
OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EOUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
1.
2.
Arc welders, power sources and components
Original main power rectifiers
Ilabor
3.
4.
S
All
-
.
.
3 years
5.
Replacement
Batteries
or
EXCEPT
1 year
onlyl
feeder/guns
90 days
1 year
repair parts, exclusive of labor
AS
WRITING,
,
welding guns and
All other Millermatic Feeders
6.
1 year
.
EXPRESSLY
MILLER
ULTIMATE
BY
PURCHASE
60 days
EXPERIENCED
6 months
in writing within
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
~
I
USERS AND FOR OPERATION BY PERSONS TRAINED AND
WELDING
IN
THE
EOUIPMENT
USE
AND
CONSUMER USE. MILLER
provided that Miller is notified
PROVIDED
PRODUCTS
thirty 1301 days
TO,
of the date of such failure.
AND
MILLERS
NO
RESELLER
MAINTENANCE
FOR
CONSUMERS
OF
(
OR
~
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
WARRANTIES TO, ANY CONSUMER.
~,crc!rct~r
.
AND
NOT
TO
EXTEND
~
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 4
-
OPERATION
Add Section 4-6. VOLT-AMPERE CURVE
The volt-ampere
Add
Figure
curve
(Figure
4-3
on
this Errata Sheet)
shows the maximum voltage and amperage output capabilities of the
welding
power source.
4-3. Volt-Ampere Curve
100
90
80
70
~
60
0
>50
U
o
40
30
20
10
I
I
0
200
400
t
600
800
I
1000
1200
1400
1600
9-047 999
DC AMPERES
Figure
AMENDMENT TO SECTION 6
Amend
Figure
6-1. Circuit
-
4-3.
Volt-Ampere Curves
TROUBLESHOOTING
Diagram For 1000 Models
L
~GRO.
POSITIVE
Circuit Diagram No. B-086 792
Figure 6-1. Circuit Diagram For 1000 Models Effective With Serial No. JC646118
11 / 1/82
OM-267C
Page
A
Amend
Figure 6-2. Circuit Diagram For 1500A Models
460V
ONLY
000 AMPERE
NEGATIVE
SECTION
POSITIVE
Circuit Diagram No. B-088 038
Figure
OM-267C Page B
6-2. Circuit
Diagram
For 1500A Models Effective With Serial No. JC646118
Amend
Figure 6-3. Circuit Diagram For 1500V Models
4~OV.
O~lt.
Y
000 AMPERE
AMPERE
SECTON
SCO
NEGATIVE
SECTION
POSITIVE
8
A
Circuit
Figure 6-3. Circuit Diagram
POSITIVE
Diagram
No. 8-088 039
For 1500V Models Effective With Serial No. JC646118
Effective With Serial No. JC646118
Quantity
Item Or
Dia.
Part
Replaced
Page No.
Mkgs.
No.
With
Wi
048 731
034 821
VS1 ,2
VS1
VR1
024 471
Deleted
Pg 2
Pg 2
Pg 2
Pg 2
Pg 2
Pg 2
Pg 2
Pg2
024 471
Ri
SRi 1
045 586
031 689
037 156
Rh
Pg 4
Pg 4
Pg 4
Pg 4
Pg 4
Pg 4
4
R12
SR12
C17
C18
604 288
083 719
031 640
601 375
031 683
044 099
044 100
Model
Description
INTERLOCK,
contactor
NO
or
1000
NC left hand
1
1
1
1
Deleted
035 645
085 294
045 586
031 689
037 156
085 294
Deleted
11500A 11500V
VARISTOR, 8 joule 150 volts
RESISTOR, WW fixed 5 watt 2000 ohm
1
1
6
6
6
1
1
1
RECTIFIER (should read)
CAPACITOR (should read)
1
1
6
6
DIODE(shouldread)
18
18
RESISTOR,WWfixed5watt2000 ohm
1
Deleted
Deleted
Deleted
Deleted
038 980
038 898
.
TERMINAL BOARD, primary
LiNK, terminal connecting
-
1
3
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-267C Page C
TABLE OF CONTENTS
Page
Section No.
SECTION 1
1
1
1
1
-
-
-
-
No.
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1.
Introduction
1
2.
General Precautions
1
3.
Arc
4.
Standards Booklet Index
SECTION 2
2- 1.
Welding
INTRODUCTION
5
General
2- 2.
Receiving-Handling
2- 3. Description
2-4. Safety
SECTION 3
3
4
5
5
5
INSTALLATION
3-1.
Location
6
3- 2.
Electrical Input Connections
6
3
-
3. Weld Output Connections
SECTION 4
4- 1.
8
OPERATION
Power Control Switch
8
4-2. Overload Protection
9
4- 3.
9
Pilot Light
4-4. Meters
9
4- 5.
9
SECTION 5
Duty Cycle
MAINTENANCE
5-1.
FanMotor
9
5- 2.
Internal
Cleaning
9
Control Circuit Protection
9
5
-
3.
SECTION 6
TROUBLESHOOTING
1-SAFETY RULES FOR OPERATION OF ARC
SECTION
1-1.
of
concentrations
harmful
INTRODUCTION
POWER SOURCE
WELDING
Learning safety through personal
experience, like a child touching a hot stove is harmful,
wasteful, and unwite. Let the experience of others teach you.
We
learn
at
experience.
by
tained. The
reason
are
explain. It
wear
local
Adequate
each person in the
an
area
air-supplied respirator.
be used.
must
or
fumes should not be heated unless
in
Work
and, if
for the safe practices may not always be
on common sense, others may require
to
must
fumes.
or
containing materials that emit toxic
coating is removed from
the work surface, the area is well ventilated, or the operator
wears an air-supplied respirator.
coated with
Metals
based
technical volumes
the operator
as
For beryllium, both
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
and safe installation, operation, and servicing practices. Acci
dents occur when equipment is improperly used, or main
given. Some
well
toxic
used,
exhaust ventilation mutt be
Gas leaks in
is wiser to follow the rules.
being ventilated
air-supplied respirator.
confined space only while it is
a
necessary, while
wearing
an
confined space thould be avoided. Leaked gas
a
large quantities can change oxygen concentration danger
ously. Do not bring gas cylinders into a confined space.
in
these safe piactices 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.
Read and understand
to
Leaving confined
Check
observe these safe
practices
Failure
to
jury
death. When safety becomes
can
or
may
cause
to
-
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.
National
Health
that the space is safe before
re-entering
it.
(or flame)
arc
to form
can be decomposed by the
PHOSGENE, a highly toxic
other
gene. DO NOT WELD
drawn into the welding
or
where solvent
cut
vapors
can
be
or cutting atmosphere or where the
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.
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.
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
source
lung and eye irritating products. The ultra
gas,
violet (radiant) energy of the arc can alto decompose sri
chioroethylene and perchloroethylene vapors to form phos
safe practices are divided into two Sections: 1
General Precautions, common to arc welding and cutting; and
2- Arc Welding (and Cutting)(only).
These
A.
sure
Vapors from chlorinated solvents
and
1-2.
be
heat of the
be used with confidence.
The
at
serious in
habit, the equipment
a
OFF gas supply
space, shut
prevent possible accumulation of gases in the space if down
valves have been accidently opened or left open.
stream
-
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, and
(in electrical parts) of metallic particles that can cause short
circuits.
glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear cover 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.
safety goggles
Wear helmet with
or
See 1-3A.2.
If combustibles
are
in area, do NOT weld
or
cut.
Move the
practicable, to an area free of combustibles. Avoid
pains spray rooms, dip tanks, storage areas, ventilasors. If the
work cannot be moved, move combustibles at least 35 fees
away out of reach of sparks and heat; or protect against
if
work
ignition
with suitable and
snug-fitting, fire-resistant
covers or
shields.
Avoid oily
Hot
metal
never
clothing.
greasy
or
such
A
spark
electrode stubs
be handled without gloves.
may
and
as
ignite them.
workpieces should
Walls touching combustibles
welded on (or cut). Walls,
Medical first aid and eye treatment. First aid facilities and a
first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns.
Fire
b.
c.
Flammable hair preparations should
intending to weld or cut.
not
be used
by persons
d.
Toxic Fume Prevention
watcher
Z49.1
1
listed
in
Hot
Standards
index. NEVER ventilate
with oxygen.
Lead
and
-.
cadmium
similar
,
zinc
-.
mercury
-.
materials, when welded
and beryllium
(or cut)
may
bearing
produce
-
be
floor
covers or
standing by
and
and
with
not be
near, work
shields.
suitable
fire
ex
for some time after weld
appreciable combustibles (including building construc
tion) are within 35 feet
appreciable combustibles are further than 35 feet but can
be ignited by sparks
openings (concealed or visible) in floors or walls within 35
feet may expose combustibles so sparks
combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radians or conducted heat.
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
must
tinguishing equipment during
ing or cutting if:
a.
Ear plugs should be worn when working on overhead or in a
confined space. A hard hat should be worn when others work
overhead.
dard
opposite sides should
ceilings,
should be protected by heat-resistant
qualified
B.
on
supervisors
be
approval
obtained
that
before operation to
adequate precautions have
been taken.
After work is done, check that
embers, and flames.
area
is free of
sparks, glowing
An empty container that held combustibles, or that can pro
duce flammable or toxic vapors when heated, must never be
welded on or cut, unless container has first been cleaned as
described in AWS Standard A6.O, listed 3 in Standards index.
OM-267 Page 1
thorough 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.
includes:
This
solvent
a
water
or
contents should be cleaned (see
Do NOT depend on sense of smell or sight
fit is safe to weld or cut,
A container with
unknown
cylinders particularly valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
Protect
cylinders.
Stuck
Do NOT
valve.
cylinder
supplier.
valve that
can
hammer
or
wrench
use
a
not
be opened by hand.
to
open
Notify
a
your
paragraph above).
to determine
Hollow castings
or
or
cutting. They
containers
can
must
be vented before
weld
or cut
welding
Mixing gases.
Never try to mix any gases in
Never refill any cylinder.
explode.
Cylinder fittings should
Explosive atmospheres. Never
Contain
cylinder.
a
flammable dust, gas,
or
liquid
never
be modified
or
exchanged.
where the air may
vapors
(such
as
gaso
Hose
3.
line),
Prohibited
D.
Never
use.
use
hose other than that
designed
for
Compressed Gas Equipment
the
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.
Use ferrules or clamps designed for the hose (not ordinary
wire or other substitute) as a binding to connect hoses to
gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
specified
Standard
No copper
splice hose.
Pressure Regulators
1.
fittings.
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
tubing splices.
Use only standard brass
fittings
to
Regulator
from
tor
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
excess
Remove faulty regulator from service immediately for repair
(first close cylinder valve). The following symptoms indicate
slag, and
relief devices.
more
Examine
faulty regulator:
tions.
if gas leaks externally.
Leaks
Excessive Creep
if delivery pressure continues to rise with
downstream valve closed.
if gauge pointer does not move off stop pin
Faulty Gauge
when pressurized, nor returns to stop pin after pressure
release.
-
prevent kinks and abuse. Suspend hose off
being run over, stepped on, or other
hose to prevent kinks and
Protect hose
a
to
it from
from
tangles.
damage by sharp edges, and by sparks,
open flame.
hose
regularly for leaks,
pressured hose in
Immerse
wear,
and loose
water;
bubbles
connec
indicate
leaks.
-
-
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.
2.
Cylinders
Cylinders
damage
be handled carefully to prevent
their walls, valves, or safety devices:
must
to
leaks and
Repair leaky
or
4.
hose by
worn
)i-2D3). Do NOT
use
cutting
area
Out
and
splicing
tape.
Proper Connections
Clean
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 lint
lets 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
cylindercontaining any other gas.
the
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,)
ICC
or
DOT
assurance
of
Identifying
marked
on
marking must be on each cylinder. It is
safety when the cylinder is properly handled.
an
gas content. Use only cylinders with name of gas
them; do not rely on color to identify gas con
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec
tion leaks, disassemble, clean, and retighten using properly
fitting wrench.
Adapters. Use a CGA adapter (avaiable from your supplier)
cylinder and regulator, if one is required. Use two
wrenches to tighten adapter marked RIGHT and LEFT
tent.
Notify supplier if unmarked. NEVER DEFACE or alter
name, number, or other markings on a cylinder. It is illegal
between
and hazardous.
HAND threads.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
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.
Prohibited use. Never use a cylinder or its
than its intended use. NEVER as a support
Locate
or
secure
Passageways and
cylindes
work
so
areas.
they
contents for other
or
cannot be
5.
roller.
knocked
Keep cylinders clear of
over.
areas
where they may be struck.
Transporting cylinders. With a crane, use a secure support
as a platform or cradle. Do NOT lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag
such
nets.
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.
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 regu
lator maxlmum( 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.
creases
Do NOT expose cylinders
flame,
exceed
exists.
Page
2
130F.
to
excessive
heat, sparks, slag, and
not allow contents to
Cool with water spray where such exposure
etc. that may cause
rupture. Do
Use
and
operation with low-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
safe
pressure charts (available from your supplier( for
efficient, recommended pressure settings on regulators.
level.
for leaks
Check
Brush with soap
after.
pressurization
solution (capful
first
on
regularly there
of Ivory Liquidt or
and
Viewing the weld. Provide face shields for
looking directly at she weld.
equivalent per gallon of waser(. Bubbles indicate leak. Clean
all
persons who
are
weanng flash
will be
off soapy water after test; dried soap is combustible.
Others working in
E.
User
Responsibilities
See that all persons
area.
goggles.
Remove leaky or defective equipment from service immed
iately for repair. See User Responsibility statement in equip
starting
Before
doors
are
weld, make
to
sure
that
screen
flaps
or
bay
closed.
ment manual.
F.
Leaving Equipment Unattended
Close gas
G.
supply
at source
B.
and drain gas.
Comply
Rope Staging-Support
or
C.
invites
is
tafe process, but
a
a
equipment.
rated
capacity.
Loose cable connections
fire.
are
Never strike an
bristle
described here and in
creates a
to
Burn Protection
D.
Comply with precautions in 1-2.
Do not
overload
cause a
welding
arc
fire.
such
a
arc
on
area
a
that
overheat
may
cylinder
can
or
cause
or
flash and
cause
a
other pressure vessel. Is
violent rupture or lead
a
rupture later under rough handling.
Compressed Gas Equipment
Comply with precautions in 1-2D.
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
WITH PRECAUTIONS.
Protective
in 1-2C.
It may overheat cables and
fumes
others from accidents. Precautions
standards referenced in index.
be vented to the outside air.
must
at
significant voltages,
1.
in 1-2B.
Explosion Prevention
Equipments
careless opera
trouble, The equipment carries high currents
The arc is very bright and hot, Sparks fly,
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
A.
Fire and
Comply with precautions
1-1, 1-2, and this section. Arc
in
precautions
Welding, properly done,
tor
precautions
cut
ARC WELDING
Comply with
with
Generator engine exhaust
Carbon monoxide can kill.
Rope staging-support should not be used for welding
ting operation; rope may burn.
1-3.
Toxic Fume Prevention
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 sur
face when welding, without suitable protection.
Clothing
To protect
Iong.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
against
shock:
Wear
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
reduces
and an electrically HOT part
or grounded metal
the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
-
Bare skin protection. Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre
vent entry of sparks.
1.
2.
Grounding
the
-
Equipment
Eye and Head Protection
installing, connect the frames of each unit such as
welding power source, control, work table, and water circula
tor 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 liquid such as oil or fuel.
When
Protect eyes from exposure
tric arc without protection.
Welding helmet
12
or
before
or
denser
must
striking
arc.
Protect filter
Cracked
radiation
containing
shield
can
plate with
pass
a
an
elec
filter plate shade no.
Place over face
be used when welding.
a
clear
broken helmet
or
NEVER look at
so arc.
through
cover
or
plate.
shield should NOT be worn;
to cause burns.
Cracked, broken, or loose filter plates muss be replaced IM
MEDIATELY. Replace clear cover plate when broken, pitted,
or spattered.
Three-phase connection. Check phase requirement of equip
If only 3-phase power is available,
ment before installing.
two wires of the
connect single-phase equipment to only
3-phase line. Do NOT connect the equipment ground lead to
the third (live( wire, or the equipment will become electri
a dangerous condition that can shock, possibly
cally HOT
fatally.
-
Before
Flash
goggles
helmet to give
not be
lowered
MUST be worn under the
protection to the eyes should the helmet
the face before an arc is struck. Looking
side shields
with
some
over
an arc momentarily with unprotected eyes (particularly a
high intensity gas-shielded arc( can cause a retinal burn that
at
may leave
3.
a
permanent dark
area
in the field of vision.
Protection of Nearby Personnel
tors
welding, check ground for continuity. Be sure conduc
touching bare metal of equipment frames at connec
are
tions.
line cord with a ground lead is provided with the equip
for connection to a switchbox, connect the ground lead
so the grounded switchbox. If a three-prong 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
If
a
ment
with a three-prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
comes
Enclosed
room
or
Trademark
welding
area.
For
production welding,
enclosed bay is best.
of Proctor & Gamble.
In
separate
open areas, surround the
a
OM-267 Page 3
2.
Electrode Holders
Do
power circuit or change polarity while welding.
emergency, it must be disconnected, guard against
shock burns, or flash from switch arcing.
not open
If,
Fully insulated electrode holders should
holders with protruding screws.
be used.
Do NOT
in
an
use
3.
Leaving equipment unattended. Always shut OFF and dis
all power to equipment.
Connectors
connect
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 be
available
near
the
welding
source.
STANDARDS BOOKLET INDEX
For
more
information,
their latest revisions and
refer to the
comply
es
following standards
applicable:
or
-
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks.
Terminals And Other
5.
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.
American Welding Society Standard A6.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
Exposed Parts
Terminals and other exposed parts of electrical units should
insulating covers secured before operation.
have
6.
1.
COMBUSTIBLES,
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
4.
Safety Devices
Safety
not
devices such
be disconnected
as
or
interlocks and circuit breakers should
shunted out.
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
volts line-cord plugs.
Page
4
Standard
WELDING
same as
item 1.
OXYGEN-FUEL GAS SYSTEMS
CUTTING, obtainable from the
National
Fire Protection Association, 470 AtlantIc
Avenue, Boston, Mass. 02210.
FOR
other HOT parts.
7.
NFPA
obtainable
51,
AND
5.
NFPA Standard SiB, CUTTING AND WELDING PRO
CESSES, obtainable same as item 4.
6.
CGA Pamphlet P.1. SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N. Y. 10036.
7.
OSHA Standard 29 CFR, Part 1910,
ING, CUTTING AND BRAZING,
Subpart 0, WELD
SECTION 2
INTRODUCTION
-
Input At Rated
Load Output
Max.
Rated
Welding
Current Amperes
100% Duty Cycle
Model
60 Hz. Three-Phase
Open-
~
Amperes At
Circuit
230V
Voltage
460V
Weight
kva
575V
Dimensions
kw
41-1/8 in. (1045 mm)
Width
27-1/4 in. (692 mm)
Depth -46 in. (1168 mm)
Height
1000
1000
@76
Volts
85
224
112
89
90
85
Height
1500
@76
Volts
85
330
165
131
132
-
896 lbs.
986 lbs.
(406 kg)
(447 kg)
1068 lbs.
1158 lbs.
(484 kg)
)525 kg)
-
.
1500
Ship
Net
Width
123
-
-
Depth
41-1/8 in. (1045 mm)
27-1/4 in. (692 mm)
-46 in. (1168 mm)
Figure 2-1. Specifications
GENERAL
This manual has been prepared
especially for use in familiarizing personnel with the
design, installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein and on various labels, tags, and plates
on the unit should be given careful consideration to
assure optimum performance of this equipment.
2-1.
-
2-2. RECEIVING-HANDLING
Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
2-4. SAFETY
Before
the
equipment is put into
operation, the safety section
should be read completely.
at the front of this manual
This will
help avoid possible injury due
following definitions apply
to
-
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 will be furnished by the manufacturer on re
quest if occasion
to file
claim arises.
to
misuse
or
im
welding applications.
prooer
The
-
and
TANT,
NOTE
blocks
Under
this
CAUTION, IMPOR
throughout this
found
manual:
tif I
operating,
installation,
heading,
procedures or practices will
carefully followed may create a
and maintenance
be found that if not
hazard to personnel.
When
requesting information concerning this equip
ment, it is essential that Model Description and/or
Stock Number and Serial (or Style) Numbers of the
equipment be supplied.
2-3.
DESCRIPTION
-
This welding power
in
source
corporates a three phase Delta connected, constant
potential (CP) type main power transformer to provide
the constant voltage output required to operate the
resistance
grid welding stations
-
(Figure 3-1) A proper installation
welding power source if
-
site should be selected for the
the unit is to
relatively
I~eIl~ Under this
heading, explanatory statements
special emphasis to obtain the
will be found that need
most efficient
operation of the equipment.
connected to the unit.
SECTION 3
3-1. LOCATION
IMPORTANT Under
this
heading, installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may result in
damage to equipment.
____________
provide dependable service, and remain
maintenance free.
INSTALLATION
tions.
The installation site should also permit easy
removal of the welding power source outer enclosure
for maintenance functions.
IMPORTANT Do not place any filtering device over
the in take air passages of the welding power source as
this would restrict the volume of intake air and thereby
subject the welding power source internal components
______________
A proper installation site permits freedom of air move
ment into and out of the welding power source, and
also least subjects the unit to dust, dirt, moisture, and
to an
overheating
corrosive vapors. A minimum of 18 inches (457 mm) of
unrestricted space must be maintained between the
Warranty is void
welding
power source front and rear panels and the
obstruction. Also, the underside of the welding
power source must be kept completely free of obstruc
Holes
nearest
mounting
are
condition and
if any type of
provided
in the
subsequent failure.
filtering device is used.
welding
power
source
base for
purposes. Figure 3-1 gives overall dimensions
and the base mounting hole layout.
OM-267
Page 5
1~.tU1lIs1~ Connect
welding power
the three-phase
the input conductors to the
making connections to
source
before
power
supply.
The
input conductors should be covered with an in
sulating material which conforms to local electrical stan
dards. Table 3-1 is provided only as a guide for selecting
the proper size input conductors and fuses.
/
Table 3-1. Input Conductor And Fuse Sizes
Input Conductor Size
Model
1000
Amperes
-
AWIJ
Fuse Size In
Amperes
230V
460V
575V
230V
460V
410 (21
2 (81
4 (81
350
175
125
2/0 (4)
1/0 (6)
500
250
225
1500 Amperes 400 MCM (1/01
575V
input conductor sizes are based on National Electrical Code specifications
allowable ampacities of insulated copper conductors, having a
with not more than three conductors in a
temperature rating of 75C,
raceway or cable. Numbers in I ) are equipment ground conductor sizes.
for
*Includjng 2-7/8 in. (73 mm) Lifting Eye
Figure 3-1. Overall Dimensions And Base
Mounting Hole Layout
to extend
IMPORTANT:
The
completely
under the base.
of lift forks too short to
use
ex
_________
opposite side of the base will expose in
ternal components to damage should the tips of the lift
forks penetrate the bottom of the unit.
This
hole
on
one
the
rear
3-2 for hole location and size.
Connect the three
input conductors to the line terminals
the contactor. Connect the ground conductor to the
terminal labeled GROUND on the frame near the con
tactor. The remaining end of the ground conductor
should be connected to a proper ground. Use a groun
ding method that is acceptable to the local electrical in
The
t~.IuI I
Input Requirements
welding
power source is designed to be operated
three-phase, 60 Hertz, ac power supply which
has a line voltage rating that corresponds with one of
the electrical input voltages shown on the nameplate.
Consult the local electric utility if there is any question
from
access
spection authority.
3-2. ELECTRICAL INPUT CONNECTIONS
Electrical
through
on
tend out of the
A.
input conductors plus
the
ground con
panel. This
hole will accept standard conduit fittings. See Figure
On most welding power sources a lifting device is pro
vided for moving the unit. However, if a fork lift vehicle
is used for lifting the unit, be sure that the lift forks are
long enough
Insert the three
ductor
a
ground terminal
is connected to the
welding power source chassis and is for grounding pur
poses only. Do not connect a conductor from the
ground terminal to any one of the line terminals as this
will result in an electrically energized welding power
source
chassis.
2-5/8 in. (66.7 mm)
Dia. Access Hole
Line Terminals
about the type of electrical system available at the in
or how proper connections to the welding
stallation site
power
B.
source are to
be made.
Input Conductor Connections
U~sII~ It
is recommended that a line disconnect
switch be installed in the input circuit to the welding
This would
provide a safe and conve
completely remove all electrical power
from the welding power source whenever it is necessary
to perform any internal function on the unit.
power source.
nient
means to
Input Voltage Jumper
making electrical input connec
tions to the welding power source, machinery lockout
procedures should be employed. If the connection is
to be made from a line disconnect switch, the switch
should be padlocked in the open position. If the connec
tion is made from
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, or other discon
necting
tag
to
Page
6
device without
on.
*1 000 Model Illustrated
Figure
C.
locking facilities,
warn
attach
others that the circuit is
a
3-2.
TB-079 825
Input Conductor Connections
Matching The Welding Power Source
Input Voltage
To
The Available
a
the device to
worked
Links*
Before
t~..tUI I
1.
For 1000 And 1500 Models
red
being
The
input voltage jumper links provided on the primary
permit the welding power source to be
terminal board
operated
voltages
from
various
line
The
voltages.
various
i0
from which this unit may be
the nameplate and on the input
operated are
stated on
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 voltges 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.
I
101
LJ
L_J
r~
r--~
101
I
0
I
I
I
101
U
IQU
LJ
r-
r~
r
101
0
I
I
I
I,-~I
L_J
loP
0
I
I
I
230 VOLTS
I
0
0
I
I
I
I
I
0
J
I~i
L_J
(460V)
(437V)
460 VOLTS
(483V)
TA-044 915
16
61
10
01
o
10
01
o
10
0!
16
61
o
16
6
0
10
61
10
01
o
10
01
0
Figure 3-4. Line Voltage Compensation Selection
Taps For 1500V Models
CAUTION: Ensure that the unit is
down before
A.
0
059 530
making
completely shut
any weld output connections.
Location
The POSITIVE and NEGATIVE weld output terminals
located on the lower portion of the front panel.
are
Figure 3-3. Input Voltage Jumper Link Arrange
ment
B.
If
only one jumper link is required on each of
the grouped terminals, it is recommended that the
unused jumper links be placed across the terminals
which are to be used. This will pre vent losing the jumper
links which are not required for this connection.
Ii1Is)l~ If
Welding Cables
welding
cables
were not
ordered with this unit, the
to ensure the best
steps listed should be followed
welding performance:
1.
It is recommended that the
primary of the main transformer has three selection
to allow compensation for a high or low incoming
line voltage. Selection is made at the primary terminal
board. The taps on the primary terminal board are mark
ed in percentage: +5%, 0, and -5%. If the line voltage
is high, the +5% tap would be used. If line voltage is
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. Proper operation is to a great extent
dependent on the use of welding cables and con
nections that are in good condition and of ade
low, the -5% tap would be used.
quate size.
For 1500V Models
2.
The
taps
the
primary
same
percent
The welding power source is shipped from the
with the links set at zero percent compensation.
factory
Thus, if
IMPORTANT All three
jumper links
on
terminal board must be connected for the
2.
compensation.
Use Table 3-2 as a guide for selecting 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 weld current
that is to be used.
voltage is relatively close to the requirement, the
position of the jumper links need not to be changed.
line
3.
Do not
unit, it is
4.
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
Use correct lugs on the weld cables to connect
them to the weld output terminals.
5.
Ensure that all connections
3-3. WELD
3-5)
-
OUTPUT
CONNECTIONS
To obtain the full rated output from this
use
damaged
or
frayed cables.
(Figure
are
clean and
tight.
OM-267
Page
7
Table 3-2.
Welding
Welding Cable Size
Total
Amperes. DC
50
Length Of Cable (Copper)
100
150
200
250
In Weld Circuit
300
350
400
100
4
4
2
2
2
1
1/0
i/O
150
2
2
2
1
1/0
2/0
3/0
3/0
200
1
1
1
1/0
2/0
3/0
4/0
4/0
250
1/0
1/0
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
2/0
2/0
2/0
3/0
4/0
2~2/O
2-3/0
2-3/0
350
3/0
3/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
3/0
3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
4/0
4/0
2-2/0
2-3/0
2-4/0
600
4/0
4/0
4/0
2-2/0
2-3/0
700
4/0
4/0
2-3/0
2-4/0
500MCM
800
2-2/0
2-2/0
2-3/0
2-4/0
1000MCM
900
2-3/0
2-3/0
2-4/0
500MCM
1000
2-3/0
2-3/0
2-4/0
1000MCM
500
.
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
SOOMCM
1000MCM
1000MCM
1000MCM
1750
1000MCM
1000MCM
1000MCM
1000MCM
2000
1000MCM
1000MCM
1000MCM
TA-052 764
NOTE:
A
5OFEETORLESS.
B.
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.
I WiI ~i] l VU I ~ Select
DC
DC Pocitivo
'
'
'
DC Positive
Negetivo
'
DC Nogetivo
'
'
__
'
A
'
'
'
'
B
A
B
A
'
'
'
B
A
B
1.
When
1000 AMP POSITION
500 AMP POSITION
the desired polarity before
making weld output connections. Choose either dc
straight polarity (electrode negative) or reverse polarity
(electrode positive).
079 746
ween
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
A
B
A
B
A
B
A
B
the
weld
output
terminals
are
not
bused
amperes of weld output is available bet
the A Positive and A Negative output terminals.
together, 500
1000 Ampere Models
'
For 1000 Ampere Models
Simultaneously, 500 amperes of weld output is
available between the B Positive and B Negative output
terminals.
500-1000 AMP POSITION
1500
1500 AMP POSITION
Ampere Models
TA-084 430
Figure 3-5. Weld Output Connections
C.
Weld
Output Connections (Figure 3-5)
These units have two separate weld output sections, A
and B, that must be considered when making connec
tions.
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.
This unit
bused
was shipped with the weld output terminals
together (in the 1000 ampere position; see Figure
3-5).
2.
When
For 1500
the
Ampere Models
weld
output
terminals
are
not
bused
together, 500
CAUTION ELECTRIC SHOCK can kill.
Do not touch five electrical parts.
S
Shut down the
we/ding power source and discon
nect input power before making weld output con
ween
amperes of weld output is available bet
the A Positive and A Negative output terminals.
Simultaneously, 1000 amperes of weld output is
available between the B Positive and B Negative output
terminals.
nections.
Do not make connections
to weld output ter
minals of the different sections (A and B) unless
the bus bars are in p/ace.
If the
positive output terminal of one section (A, for ex
ample) is connected to the negative output terminal of
the other section (B, for example), two times the normal
output voltage will exist between the remaining two
output terminals. Consult applicable safety codes.
Page8
When the weld output terminals are bused together,
1500 amperes of weld output is available between the A
Positive and A Negative
output terminals.
This unit
bused
3-5).
or
B Positive and B
Negative
was shipped with the weld output terminals
together (in the 1500 ampere position; see Figure
SECTION 4
Pilot
OPERATION
Circuit breaker CB protects the welding power source
excessive secondary current draw. Current
transformer CT1 and CT2, located in the secondary of
Circuit
Breaker
-
from
Light
Ammeter A
Ammeter B
the
main
transformer,
..Voltmeter
Voltmeter A
B
sense
overloading
draw. Should
ing the contactor
operations.
to
the
secondary
current
occur, CB would open caus
drop
out
thereby suspending all
Start And
Stop Buttons
place the welding power
To
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 probably present. Do not attempt
any further welding until the trouble has been remedied.
4-3.
LIGHT
PILOT
when the
welding
-
The
PL1
pilot light
power source is in
a
indicates
ready-to-weld
status.
The meters are provided to monitor
METERS
welding operation. They are not intended for exact
current or voltage measurements. These meters are in
ternally connected to the output terminals. The
voltmeters will indicate the voltage at the output ter
minals, but not necessarily the actual voltage at the
welding arc (due to cable resistance, poor connections,
4-4.
-
the
DC Positive*
DC
Negative
TB079824
*1000 Models Illustrated
Figure
4-1.
4-1. Front Panel
POWER CONTROL SWITCH
etc.). The ammeters will indicate the
(Figure 4-1)
current
output of
the unit.
the
POWER CONTROL
CAUTION Depressing
STOP button does not remove power from all of the
we/ding power source interna/ circuitry. Completely ter
minate all electrical power to the welding power source
_________
by employing machinery lockout procedures before
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 posi
the fuses and
tion. If connected to a fuse box, remove
padlock the cover in a closed position. If the unit is
MODEL
2000
Lu
uJ
0~
<
GPS-1500
1500
z
0
-I
LU
con
nected to a circuit breaker, or other disconnecting
device without locking facilities, attach a red tag to the
device to warn others that the circuit is being worked
GPS -10 00
1000
40
50
60
70
80
90 100
% DUTY CYCLE
B-079809
on.
Figure 4-2. Duty Cycle Chart
Depressing the POWER CONTROL START button will
energize the welding power source placing the unit in a
ready-to-weld status. Depressing the POWER CON
TROL STOP button will shut the welding power source
down.
4-5.
CYCLE
DUTY
The duty cycle of a welding
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
power
-
source
be safely operated at rated load continuous
ly. Figure 4-2 enables the operator to determine the safe
output of the welding power source at various duty
cycles.
source can
Thermostat TP1,
4-2. OVERLOAD PROTECTION
located in the main transformer, is wired into the con
-
Should overheating occur, TP1
causing the contactor to drop out thereby
suspending all operations. If TP1 opens, allow the unit
to cool before resuming operations.
tactor W coil circuit.
would open
Exceeding the indicated duty cycle
overheating and thereby damage to the
~
will
cause
welding
power
source.
OM-267
Page
9
SECTION 5- MAINTENANCE
CAUTION:
Depressing
the
POWER
CONTROL
STOP button does not
remove power from all of the
power source internal circuitry. Completely ter
minate all electrical power to the welding power source
welding
by employing machinery lockout procedures before
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 posi
tion. If connected to
padlock the
fuse box,
in the closed
a
remove
the fuses and
position. If the unit is
breaker, or other disconnecting
device without locking facilities, attach a red tag to the
cover
connected to
device to
circuit
a
warn
others that the circuit is
being
worked
5-1.
FAN MOTOR
All models are equipped with an
exhaust fan and rely on forced draft for adequate cool
ing. The fan motor is manufactured with lifetime-
lubricated sealed ball bearings and
be
no
attention should
required.
5-2.
INTERNAL
out or
vacuuming
CLEANING
Occasional
-
blowing
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.
The welding power source outer enclosure should be
removed and
a
clean, dry air
should be used for this
stream or vacuum suction
cleaning operation.
on.
5-3. CONTROL CIRCUIT PROTECTION
The en
tire control circuit of the welding power source is pro
tected by a 600 volt, 3 ampere, cartridge type fuse Fl.
This fuse is located under the top cover beside contac
tor W. Should this fuse open, the welding power soure
-
IMPORTANT:
unit for
Periodically inspect the labels on this
legibility. All labels must be maintained in a
clearly readable
state and replaced when necessary.
See the Parts List for part number of labels.
SECTION 6
-
It is assumed that proper installation has been made, ac
to Section 3 of this manual, and that the
power source has been
until this trouble developed.
functioning properly
Use this chart in
conjunction with the circuit diagram
performing troubleshooting procedures. If the
trouble is not remedied after performing these pro
while
cedures, the
nearest
Factory Authorized Service Sta
tion should be contacted.
malfunction,
the
In all
cases
manufacturers
of
completely shut down.
TROUBLESHOOTING
cording
welding
would
equipment
recommendations
I~ I
ternal
Hazardous voltages
circuitry
power is
of the
welding
connected to
are
power
present
on
source as
the in
long
Disconnect power
before attempting any inspection or work on the inside
of the unit. Troubleshooting of internal circuitry should
be performed by qualified personnel only.
The
following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding power source.
should be strictly followed.
TROUBLE
No output.
PROBABLE CAUSE
Thermostat TP1 open.
REMEDY
Allow unit
a
cooling period.
Replace defective TP1.
Circuit breaker CB open.
Reset CB.
Replace defective CB.
Fuse Fl is blown.
*lf it becomes necessary to
type, and rating is used.
Page
10
replace
any fuse in the
*Replace defective Fl.
welding
as
the unit.
power source,
ensure
that
a
fuse of the proper size,
p
B
POSITIVE
Circuit Diagram No. B-082 509
Figure 6-1. Circuit Diagram For 1000 Models
460V
ONLY
500
NEGATIVE
fl~ORQF
y,)~
000
POSITIVE
NEGATIVE
A*,PFPF
sFcrft)~
POSITIVE
A
Circuit Diagram No. B-083 538-A
Figure 6-2. Circuit Diagram For 1500A Models
OM-267 Page 11
O~LV
L~
~RD
Circuit
Figure 6-3. Circuit Diagram For 1500V Models
Page
12
Diagram
No. B-083 535-A
October 1981
FORM: OM-267C
Effective With Serial No. JB522183
PARTS
LIST
Figure
OM-267
Page
1
A
Left Side View
Quantity
Item
Dia.
No.
Mkgs.
Figure
+
059 572
070 558
3
T2
036 630
4
W
048 597
4
W
004 104
048599
004259
Wi
5
Fl
6
7
7
*048
*004
048
*604
600
258
731
259
012 638
SRi ,l 1
SRi
079 827
VS1,2
024 471
VS1
024 471
079 827
037 157
031 689
7
SRi 1
045 586
031 689
037 156
Vi
8
Description
1000
COVER, opening exit cable
PANEL, rear
TRANSFORMER; control 100 VA 115-230/460
CONTACTOR, 3 pole 110-120/208-240 (consisting of)
CONTACTOR, 3 pole 210 amp 600 V w/i 15 VAC (con
sisting of)
.COIL,115/23Ovolts
.COIL,l20voltsac
KIT, point contact
KIT, point contact
INTERLOCK, contactor normally open
FUSE, cartridge 30 amp 600 volts
HOLDER, fuse-cartridge3o amp 600 volts
RECTIFIER, silicon diode (consisting of)
RECTIFIER, silicon diode (consisting of)
SUPPRESSOR, 1 uf 2.7 ohm
025 638
9
,2
A1,2
059 118
9
Al
059 118
9
10
A2
044 104
PB1
011 636
ii
PL1
*027 629
027 631
-
-
.
CB
13
14
15
Shunt
15
Shunt
16
1500A
1500V
1
1
1
1
1
1
1
1
1
1
1
.
SUPPRESSOR, 1 uf 2.7 ohm
DIODE, rectifier275 amp 250 volts straight polarity
CAPACITOR, ceramic 0.01 uf 500 volts
RECTIFIER, silicon diode (consisting of)
CAPACITOR, ceramic 0.01 uf 500 volts
DIODE, rectifier 275 amp 250 volts straight polarity
METER, volts dc 0-100 scale
METER, ampdc5o MVO-800 scale
METER, ampdc5O MVO-800 scale
METER, ampdc5o MVO-l.5Kscale
SWITCH, push button start stop 60 amp 110 volts
BULB, incandescent slide base 120 volts
1
1
1
1
1
-
-
1
1
.
1
1
1
1
1
1
1
1
1
1
1
1
2
1
.
12
12
1
12
.
6
6
6
.
1
6
.
2
18
2
1
1
.
-
-
2
2
1
1
1
1
1
1
1
1
HOUSING, light slide base 125 volts
027 628 LENS, light red clear
034 945 CIRCUITBREAKER, manualreset2P5amp240voltsac
1
1
1
1
1
1
1
1
1
059 563
1
1
1
-
-
-
12
f
Left Side View
A
1
2
Model
Part
No.
BAFFLE, air
-
top rectifier
059 616
1
1
1
079 388
1
1
1
1
1
BRACKET, mounting-terminal board
SHUNT, meter 50 MV 800 amp
072 425 SHUNT, meter 50 MV 1500 amp
059 567 TERMINAL, power output (consisting of)
-
601 841
601 842
.NUT,brass-hexjam5/8-11
.
059 566
.
038 909
.
602 249
602 219
038 032
NUT, brass
hex full 5/8-il
.
1
16
16
16
8
8
2
2
8
2
STUD, brass 5/8-li x 3
WASHER, flat SAE 5/8
WASHER, lock external
8
8
8
8
8
8
8
8
8
4
4
4
-
-
.
1
TERMINAL BOARD
-
.
1
BUS BAR
tooth 5/8
Spare Parts.
ordering a component originally displaying
*Recommended
When
a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
+
OM-267 Page 2
2\
28
29
.
I
IT
1~
1~~
1
32
Figure
Page 3
B
Right Side
View
p
/
/
Quantity
Item
D~.
Part
No.
cvlkgs.
No.
Figure
Model
1000
Description
Right Side
B
27
009 139
28
070 556
Ri 1
030 691
R12
604 288
SR12
083 719
Ci 7
031 640
C18
031 683
29
TEl
059 555
29
TEl
044 098
601 375
038 897
044 099
602 221
1
1
RESISTOR, carbon 1 watt 4700 ohm
RESISTOR; WWfixed i0watt2 ohm
RECTIFIER, silicon control
CAPACITOR, electrolytic 500 uf 200 volts
RING, mounting capacitor
CAPACITOR,paperoilo.5uf200voltsdc
TERMINAL, primary (consisting of)
TERMINAL, primary (consisting of)
TERMINAL BOARD, primary
-
dc
.
TERMINAL BOARD, primary
WASHER, lock internal tooth3/8
-
.WASHER,flat-SAE3/8
NUT, brass- hex 3/8-16
BLOCK, terminal 30 amp 4 pole
038 804
STUD, brass3/8-16x2-i/2
038 898
LINK, terminal connecting
010910
TE2
601 837
038 621
.
-
.
044 100
Ri
30
31
32
FM
LINK, jumper terminal block 30
LINK, terminal connecting
-
.
amp
083 640 RESISTOR, grid
083 637 WINDTUNNEL, 20 inch
014 425 BAR, support-windtunnel
032616
BLADE,fan6oHz2oinch3wing2ideg
032 605 MOTOR, i/4hp23Ovoltsaci625rpm
059 983 BUS BAR, jumper secondary
34
Ti
34
Ti
34
Ti
1
1
1
1
1
1
1
1
2
1
1
1
1
1
12
12
18
12
12
18
36
36
54
12
12
18
6
6
1
3
1
1
1
i
1
1
2
2
2
1
1
i
1
1
2
2
2
070644 BASE
079 718 TRANSFORMER, power-main (consisting of)
070 897 TRANSFORMER, power main (consisting of)
044 147 TRANSFORMER, power-main (consisting of)
TRANSFORMER SUBASSEMBLY
**079 719
**~59 576 .TRANSFORMER SUBASSEMBLY
1
1
1
**079 529
6
-
33
1
-
.
1500V
1
.
.
038 620
J
1
-
.
1500A
View
VISOR, front-top
PANEL, front
.
I
1
-
.
070 555
COIL, primary/secondary
COIL, primary/secondary
COIL, primary/secondary
TRANSFORMER, current 300/5
TRANSFORMER, current 800/5
THERMOSTAT, normally closed (located in coils)
PANEL, side
COVER, top
OiOOi4
CLAMP
026 627
GASKET, lifting
**070 724
**045 971
35
35
CT1,2
CT1,2
080 075
TP1
026 181
036 612
071 624
**Replace
at
Factory
or
.
1
6
.
6
.
2
2
2
6
6
6
2
2
2
i
1
2
eye
-
cover
i
2
1
Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-267
Page
4
N
N
.~