Miller Electric GPS-1000 User manual

November
1986
FORM:
OM-267E
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST,
P.O.
Box 1079
APPLETON,
WI
54912
USA
IMPORTANT
Read
and
understand
the entire
contents of this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only by
persons
trained
and
experienced
in the
safe
operation
of
welding equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you do
not
fully
understand
these
instructions.
Effective
With
Serial
No.
JF887698
MODEL
GPS-1
000
G
PS-i
500A
GPS-1500V
OWN
ERS
MAN
UAL
A1IHER
*Ltlpv
PRINTED IN
U.S.A.

LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi
tions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
Miller is
free
from
defect
in
workman
Ship
and
material
as
of
the
time
and
place
of
delivery by
Miller.
No
warranty
is
made
by
Miller with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others. Such
engines,
trade accessories
and
other items
are
sold
subject
to
the
warranties of
their
respective
manufacturers,
if
any
.
All
engines
are
warranted
by
their
manufacturer
for
one
year
from
date of
original
purchase,
except
Tecumseh
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components having
normal
useful
life of less
than
one
(1)
year,
such
as
spot
welder
tips, relay
and
contactor
points,
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.
Miller shall be
required
to honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
within the
following
periods
from the
date of
delivery
of
Equip
ment
to the
original
user:
Arc
welders,
power
sources,
robots,
and
components
1
year
Load
banks
1
year
Original
main
power
rectifiers 3
years
(labor
-
1
year
only)
All
welding
guns,
feeder/guns
and
plasma
torches...
90
days
All
other
Millermatic
Feeders 1
year
Replacement
or
repair parts,
exclusive
of
labor
..
60
days
Batteries 6
months
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers risk and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
Appleton,
Wisconsin,
or
F.O.B.,
at
a
MILLER authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind will
be
allowed.
Upon
receipt
of notice of
apparent
defect
or
failure,
Miller shall instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN AND
ANY IMPLIED
WARRANTY,
GUARANTY OR
REPRESENTA
liON
AS
TO
PERFORMANCE,
AND ANY REMEDY FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE OR
COURSE
OF
DEALING,
INCLUDING
ANY IMPLIED
WARRANTY OF
MERCHANTABILITY
OR OF
FITNESS
FOR PARTICULAR
PURPOSE,
WITH RESPECT TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY MILLER IS
EX
CLUDED
AND
DISCLAIMED BY
MILLER.

L
1
&~~L

LIMITED
WARRANTY
*
EFFECTIVE:
OCTOBER
1,
1986
This
warranty
supersedes
all
previous
MILLER
warranties
and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
*
*
2.
r
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
!,
4.
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
(
5.
ULTIMATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
~
6.
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED AND
~
7.
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING EQUIPMENT
AND NOT FOR
CONSUMERS
OR
~,)
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
CONSUMER USE.
MILLERS WARRANTIES
DO
NOT
EXTEND
t~
t-
of
the date
of
such failure.
TO,
AND NO
RESELLER IS
AUTHORIZED
TO
EXTEND
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
r
submitted
by
the
original
user
within
the
foregoing periods.
~
~.
,~.
~
...~
~
~ ~
,,t

ERRATA
SHEET
After this manual
was
printed,
refinements
in
equipment
design
occurred. This
sheet
lists
exceptions
to
data
appearing
later
in
this manual.
**FirSt
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE MODEL
AND SERIAL
NUMBER WHEN ORDERING
REPLACEMENT
PARTS.
Dia.
**
Mkgs.
Part
No.
Replaced
With
Descnption
Quantity
2-1
2-4
2-
059
572
004 104
004259
120 496
099 044
048599
PLATE,
adapter-power
cord
CONTACTOR,
3P
110/120/220-240
(Eff
w/JH282902)
.
.
~COIL
..
1
1
1
2-
004 258
Deleted
4-27
009
139
Deleted
4-
601 375 Deleted
4-
030
691
Deleted
4-
604
288
Deleted
4-
083
719
Deleted
4-
031
640 Deleted
4-
601 375 Deleted
4-
031 683
Deleted
4-
4-
4-
4-
R2
TP1
083
640
014 425
092
624
071
624
083
640
Deleted
092
624
120
495
109
035
RESISTOR
(dia mkg changed)
(Eff w/JJ355208)
THERMOSTAT,
NC
(Part
of
transformer
assembly)
PANEL,
side
(Effw/JJ355208)
LABEL,
warning
panel
1
1
2

TABLE
OF CONTENTS
Section
No.
Page
No.

SECTION
1
-
SAFETY
RULES
FOR
OPERATION OF
ARC WELDING POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General Precautions
1
1
-3.
ArcWelding
7
1
-
4.
Standards
Booklet Index
11
SECTION
2
-
INTRODUCTION
2-1.
General
13
2
-
2.
Receiving-Handling
13
2
-
3.
Description
13
2-4.
Safety
13
SECTION 3
-
INSTALLATION
3-1.
Location
13
3
-
2.
Electrical
Input
Connections
14
3
-
3.
Weld
Output
Connections
15
SECTION
4
-
OPERATION
4
-
1.
Power
Control
Switch
17
4
-
2.
Overload
Protection
17
4-3.
Pilot
Light
17
4
-
4.
Meters 17
4 -5.
Volt-Ampere
Curve
17
4
-
6.
Duty
Cycle
17
SECTION
5
-
MAINTENANCE
5-1.
Fan
Motor
18
5
-
2.
Internal
Cleaning
18
5
-
3. Control Circuit Protection
18
SECTION
6
-
TROUBLESHOOTING