Miller GPS-1000 User manual

September
1980
FORM: OM-267B
Effective With
Serial
No.
JA372254
MODEL
GPS-1000
GPS-1
500
GPS-1500V
hullER
~
fi$IT
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETONWI54912
USA
ADDITIONAL COPY
PRICE
55
CENTS
NWSA
CODE
NO. 4579
PRINTED
IN
U.S.A.
OWNERS
MANUAL

~
~
i-
~
~-~
~~
LIMITED WARRANTY
EFFECTIVE: JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that all
new
and unused
Equipment
(
furnished
by
Miller is free from
defect in
workmanship
and
In the
case
of Millers
breach
of
warranty
or
any
other
duty
material
as
of the
time
and
place
of
delivery
by
Miller. No
war-
with
respect
to
the
quality
of
any goods,
the exclusive
remedies
ranty
is
made
by
Miller with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(11
repair
or
(21
replacement
cessories
or
other
items manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
131
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable cost
of
repair
or
replacement
at
an
authorized
the
warranties of their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase. return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall instruct
the
clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal useful
life
of less than
one
LII
year,
such
as
spot
welder
tips, relay
and
contactor
points,
ANY EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles and nozzle
insulators
where failure does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from defect
in
workmanship
or
material.
BREACH OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on war- CUSTOM
OF
TRADE
OR COURSE OF
DEALING,
INCLUDING
ranted
Equipment
in the
event
of failure
resulting
from
a
defect
ANY IMPLIED
WARRANTY OF
MERCHANTABILITY
OR OF
within the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment to
the
original
user:
ANY AND
ALL
EQUIPMENT FURNISHED
BY
MILLER IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY PROVIDED
BY
MILLER
IN
Ilabor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
Allweldinggunsandfeeder/guns
9odays
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other Millermatic Feeders
1
year
USERS
AND
FOR OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair parts,
exclusive of
labor
.
60
days
EXPERIENCED
IN THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER WARRANTIES
DO NOT
EXTEND
provided
that Miller is notified in
writing
within
thirty
1301
days TO,
AND
NO
RESELLER
IS AUTHORIZED
TO EXTEND
of
the date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
:%
J~
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j~

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.
Arc
Welding
3
1
-
4. Standards
Booklet
Index
4
SECTION
2

INTRODUCTION
2-1. General
5
2
-
2.
Receiving-Handling
5
2-
3.
Description
5
2-4.
Safety
5
SECTION
3

INSTALLATION
3-1.
Location
6
3-
2. Electrical
Input
Connections
6
3-
3.
Weld
Output
Connections
8
SECTION
4
OPERATION
4-
1. Power
Control
Switch
8
4
-
2. Overload
Protection
9
4-3.
Pilot
Light
9
4-4.
Meters
9
4
-
5.
Duty Cycle
9
SECTION
5

MAINTENANCE
5-1.
FanMotor
9
5-
2.
Internal
Cleaning
9
5
-
3.
Control
Circuit
Protection
9
SECTION
6
TROUBLESHOOTING

SECTION
1-SAFETY
RULES
FOR
OPERATION
OF ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
unwise.
Let
the
experience
of
others teach
you.
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
tained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these safe
practices
before
attempting
to
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.
Failure
to
observe these
safe
practices
may
cause
serious
in
jury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be used
with
confidence.
These
safe
practices
are
divided into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
.
Arc
Welding
(and
Cutting)(only).
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.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local industrial
codes,
and
local
in
spection
requirements
also
provide
a
basis
for
equipment
in
stallation,
use,
and
service.
GENERAL
PRECAUTIONS
Burn
Prevention
Wear
protective
clothing
-
leather
(or
asbestos)
gauntlet
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
helmet
with
safety
goggles
or
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.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs and
workpieces
should
never
be
handled without
gloves.
Medical
first
aid
and
eye
treatment. First
aid facilities
and
a
qualified
first
aid
person
should be available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of
flash
burns of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard hat
should
be
worn
when others
work
overhead.
Flammable
hair
preparations
should
not
be used
by
persons
intending
to
weld
or
cut.
B. Toxic
Fume
Prevention
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
1
in
Standards
index. NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-, mercury
-,
and
beryllium
-
bearing
and similar
materials,
when
welded
(or
cut)
may
produce
harmful concentrations
of
toxic
fumes.
Adequate
local
exhaust
ventilation must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear an
air-supplied respirator.
For
beryllium,
both
must
be used.
Metals
coated
with
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
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
concentration
danger
ously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation of
gases
in the
space
if
down
stream
valves
have
been
accidently
opened
or
left
open.
Check
so
be
sure
that
the
space
is
safe
before
re-entering
it.
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
Iradiant)
energy
of
the
arc
can
also
decompose
sri
chloroethylene
and
perchloroethylene
vapors
to
form
phos
gene.
DO NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into the
welding
or
cutting
atmosphere
or
where the
radiant
energy
can
penetrate
so
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloroethylene.
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
sighs
of
the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
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.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move the
work
if
practicable,
to
an
area
free of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
vensilators.
If she
work
cannot
be
moved,
move
combustibles
at
least
35 fees
away
out
of reach of
sparks
and
heat;
or
prosect
against
ignition
wish
suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(or cut).
Walls,
ceiiings,
and
floor
near
work
should
be
protected by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable fire
ex
tinguishing
equipment
during
and
for
some
time
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construc
tion)
are
within
35
fees
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by sparks
c.
openings
(concealed
or
visible) in
floors
or
walls within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent so
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that held
combustibles,
or
that
can
pro
duce
flammable
or
toxic
vapors
when
heated,
muss
never
be
welded
on
or
cut,
unless container
has first
been
cleaned
as
described
in
AWS
Standard
A6.O.
listed
3
in
Standards
index.
1-2.
A.
OM-267
Page
1

This
includes:
a
thorough
steam
or
caustic
cleaning
(or.
a
solvent
or
water
washing,
depending
on
the
combustibles
solubilityl
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.
A
container
with
unknown
conten~
should
be cleaned
(see
paragraph
above).
Do NOT
depend
on
sense
of smell
or
sight
to
determine
if
it
is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where the
air
may
contain flammable
dust,
gas,
or
liquid
vapors
(such
as
gaso
line).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
Drecautions
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
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regula
tor
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one or
more
relief devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than that for which the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
)first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
so
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop pin
when
pressurized,
nor
returns to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
wish
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
con
tent.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
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
contents
for other
than its
intended
use,
NEVER
as a
support
or
roller.
Locate
or secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and work
areas.
Keep
cylinders
clear of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use a secure
support
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
mag
nets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks, slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck valve. Do
NOT
use a
hammer
or
wrench to
open
a
cylinder
valve that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittin~
should
never
be modified
or
exchanged.
3.
Hose
Prohibited
use.
Never
use
hose
other than that
designed
for
the
specified
gas.
A
general
hose identification rule
is:
red for
fuel gas,
green
for
oxygen,
and
black for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordinary
wire
or
other
substitute)
as
a
binding
to connect
hoses to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fittings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
other
wise
damaged.
Coil
excess
hose
to
prevent
kinks and
tangles.
Protect
hose from
damage
by
sharp edges,
and
by
sparks,
slag,
and
open
flame.
Examine hose
regularly
for
leaks,
wear,
and
loose
connec
tions.
Immerse
pressured
hose
in
water;
bubbles
indicate
leaks.
Repair leaky
or
worn
hose
by
cutting
area
out
and
splicing
(1-2D3(.
Do NOT
use
tape.
4.
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-
less
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
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.
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
(available
from
your
supplier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches to
tighten adapter
marked RIGHT
and
LEFT
HAND
threads.
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.
5
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
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regu
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.
Pa~
2

Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for leaks
on
first
pressurization
and
regularly
there
after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak. Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from service
immed
iately
for
repair.
See User
Responsibility
statement
in
equip
ment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope staging-support
should
not
be used
for
welding
or
cut
ting
operation;
rope
may
burn.
1-3.
ARC
WELDING
Comply
with
precautions
in
1-1,
1-2.
and
this section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
opera
tor
invites trouble.
The
equipment
carries
high
currents
at
significant
yoltages.
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
.standards
referenced
in index.
A. Burn
Protection
Comply
with
precautions
in
1-2.
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
more severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition to
gloves,
hat,
and
thoes
(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.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and neck and
button
pockets
to
pre
vent
entry
of
sparks.
2.
Eye
and
Head Protection
Protect
eyes
from
exposure
to
arc.
NEVER look
at
an
elec
tric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IM
MEDIATELY.
Replace
clear
cover
plate
when
broken, pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the face
before
an arc
is struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause a
retinal
burn
that
may
leave
a
permanent
dark
area
in the
field of vision.
3.
Protection of
Nearby
Personnel
Enclosed
welding
area.
For
production welding,
a
separate
room or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with low-reflective,
non-combustible
screens
or
panels.
Allow
for
free
air
circulation,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for all
persons
who
will
be
looking
directly
at the
weld.
Others
working
in
area.
See that all
persons
are
weanng
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C. Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat cables
and
cause a
fire.
Loose cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on
a
cylinder
or
other,pressure
vessel.
It
creases
a
brittle
area
that
can cause
a
violent
rupture
or
lead
to
such
a
rupture
laser
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
wish
precautions
in
1-2D.
E. Shock
Prevention
Exposed
hot
conductors
or
other bare metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT, LIE,
LEAN
ON,
OR TOUCH
a
wet
sur
face when
welding,
without
suitable
protection.
To
protect
against
shock:
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
pars
-
or
grounded
metal
-
reduces
the
body
surface electrical
resistance,
enabling dangerous
and
possibly
lethal
currents to
flow
through
the
body.
1.
Grounding
the
Equipment
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
water
circula
tor
to
she
building
ground.
Conductors
must
be
adequate
so
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.
Three-phase
connection. Check
phase
requirement
of
equip
ment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
so
only
two
wires
of
the
3-phase
line. Do
NOT
connect
the
equipment ground
lead
to
the third
(live)
wire,
or
the
equipment
will
become
electri
cally
HOT
-
a
dangerous
condition
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conduc
tors
are
touching
bare metal
of
equipment
frames
at
connec
tions.
If
a
line cord
with
a
ground
lead
is
provided
with she
equip
ment
for connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added for
connection to
a
grounded
mating
receptacle,
the
ground
lead
must
be
connected
so
the
ground
prong
only.
If
the line
card
comes
with
a
three-prong
plug,
connect to
a
grounded
mating
receptacle.
Never
remove
she
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
Fully
insulated
electrode
holders
should be
used.
Do NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot metal and
sparks.
5. Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
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.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and circuit
breakers
should
not be
disconnected
or
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
plu~.
Do
not
open power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must be
disconnected,
guard against
shock
burns,
or
flash from switch
arcing.
Leaving equipment
unattended.
Always
shut
OFF
and
dis
connect all
power
to
equipment.
Power
disconnect switch
must
be available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
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.
American
Welding Society
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUSTIBLES,
obtainable
same
as
item 1.
4.
NFPA
Standard
51,
OXYGEN-FUEL
GAS SYSTEMS
FOR
WELDING AND
CUTTING,
obtainable
from
the
National
Fire
Protection
Association,
470
AtlantIc
Avenue,
Boston,
Mass.
02210.
5.
NFPA
Standard
51B,
CUTTING AND
WELDING
PRO
CESSES,
obtainable
same as
item
4.
6. CGA
Pamphlet
P-i. 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,
Subpart
0,
WELD
ING,
CUTTING
AND
BRAZING.
Page
4

SECTION 2
-
INTRODUCTION
Model
Rated
Welding
Current
Amperes
100%
Duty
Cycle
Max.
Open-
Circuit
Voltage
Input
At Rated
Load
Output
60
Hz. Three-Phase
Amperes
At
230V
460V
kva
kw
Dimensions
(Inches)
Weight
(Pounds)
Net
Ship
1000 1000
@
76
Volts
85 224
112
89 85
123
Height
-
41-1/8
Width
-
27-1/4
Depth
-46
896
986
1500 1500
@76
Volts
85
330 165
131
Height
-
41-1/8
Width-27-1/4
Depth
-
46
1068 1158
1500V

A
Secondary
500
@
76
Volts
B
Secondary
1000
@
76
Volts
Figure
2-1.
Specifications
2-1.
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
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
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
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.
2-4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of this manual
should
be
read
completely.
This will
help
avoid
possible injury
due
to
misuse
or
im
proper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT,
and
NOTE
blocks
found
throughout
this
manual:
CAUTION
____________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
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.
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.
2-3.
DESCRIPTION
-
This
welding
power
source
in
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
connected
to
the
unit.
I~IsII~
Under this
heading,
explanato,y
statements
will be
found
that need
special emphasis
to
obtain the
most
efficient
operation
of the
equipment.
SECTION
3
-
INSTALLATION
3-1.
LOCATION
(Figure
3-1)
-
A
proper
installation
site
should
be
selected
for
the
welding
power
source
if
the
unit
is
to
provide
dependable
service,
and
remain
relatively
maintenance
free.
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
corrosive
vapors.
A
minimum
of
18
inches
of
unrestricted
space
must
be
maintained
between
the
welding
power
source
front and
rear
panels
and
the
nearest
obstruction.
Also,
the
underside
of
the
welding
power
source must
be
kept completely
free
of
obstruc
tions.
The
installation
site should
also
permit
easy
removal
of the
welding
power
source
outer
enclosure
for
maintenance functions.
II ~ I
1s] ~I
f–I
~ I ~
Do
not
place
any
filtering
device
over
the
intake
air
passages
of the
welding
power
source
as
this
would
restrict
the volume
of
intake air
and
thereby
subject
the
we/ding
power
source
internal
components
to
an
overheating
condition
and
subsequent
failure.
Warranty
is void if
any
type
of
filtering
device
is used.
Holes
are
provided
in the
welding
power
source
base for
mounting
purposes.
Figure
3-1
gives
overall
dimensions
and the base
mounting
hole
layout.
OM-267
Page
5

lncluding
2-7/8
Lifting
Eye
Figure
3-1.
Overall
Dimensions And
Base
Mounting
Hole
Layout
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
to
extend
completely
under
the base.
~
The
use
of lift forks
too
short
to
ex
tend
out
of
the
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.
3-2.
ELECTRICAL INPUT
CONNECTIONS
A.
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
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
about
the
type
of
electrical
system
available
at
the
in
stallation
site
or
how
proper
connections
to
the
welding
power
source
are
to
be made.
B.
Input
Conductor
Connections
I~SIl~
It
is
recommended
that
a
line
disconnect
switch
be installed
in the
input
circuit
to
the
welding
power
source.
This would
provide
a
safe
and
conve
nient
means
to
completely
remove
all
electrical
power
from the
welding
power
source
whenever
it/s
necessary
to
perform
any
internal function
on
the unit.
t~.tU1IIS1~
Before
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
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;
or
other discon
necting
device without
locking
facilities,
attach
a
red
tag
to
the device
to
warn
others that the circuit is
being
worked
on.
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
I
Input
Conductor
Size
-
AWG
Fuse Size In
Amperes
Model
230V 460V
575V
230V 460V
575V
~000
Amperes
4/0
(2)
2
(8)
4
(8)
350
175
125
11500
Amperes
400
MCM
(1/0)
2/0
(4)
1/0
(6)
500
250 225
Insert the
three
input
conductors
plus
one
ground
con
ductor
through
the
access
hole
on
the
rear
panel.
This
hole will
accept
standard
conduit
fittings.
See
Figure
3-2 for
hole
location and
size.
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
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
spection
authority.
CAUTION
___________
The
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
C.
Matching
The
Welding
Power
Source
To
The Available
Input
Voltage
1.
For
1000
And
1500 Models
The
input
voltage jumper
links
provided
on
the
primary
terminal board
permit
the
welding
power
source
to
be
CAUTION:
______
Connect
the
input
conductors
to
the
welding
power
source
before
making
connections
to
the
three-phase
power
supply.
Input
conductor sizes
are
based
on
allowable
ampacities
of
insulated
cop
1B079
823
per
conductors,
having
a
temperature
rating
of
75C.
with
not
more
than
three
conductors
in
a
raceway
or
cable. Numbers
in
I
I are
equipment
ground
conductor
sizes.
source
chassis.
Input
Voltage
Jumper
Links*
*1000 Model
Illustrated
TB-079
825
Figure
3-2.
Input
Conductor
Connections
Page6

operated
from various line
voltages.
The
various
voltages
from
which
this unit
may
be
operated
are
stated
on
the
nameplate
and
on
the
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
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.
059 530
Figure
3-3.
Input
Voltage
Jumper
Link
Arrange
ment
I~IsM~
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
finks which
are
not
required
for this connection.
2.
For
1500V
Models
The
primary
of
the
main transformer has
three selection
taps
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
low,
the
-5%
tap
would
be used.
IMPORTANT
______________
All three
jumper
links
on
the
primary
terminal board
must
be connected for the
same
percent
compensation.
The
welding
power
source
is
shipped
from the
factory
with the links
set at
zero
percent
compensation.
Thus,
if
line
voltage
is
relatively
close
to
the
requirement,
the
position
of the
jumper
links need
not to
be
changed.
3-3.
WELD
OUTPUT
CONNECTIONS
(Figures
3-5
&
3-6)
-
To
obtain
the
full
rated
output
from
this
unit,
it
is
necessary
to
select,
install,
and
maintain
proper
welding
cables.
Failure
to
comply
in
any
of
these
areas
may
result
in
less
than
satisfactory
welding
perfor
mance.
(437V)
TA-044
915
Figure
3-4. Line
Voltage
Compensation
Selection
Taps
For
1500V
Models
A.
Location
The
POSITIVE
and
NEGATIVE
weld
output
terminals
are
located
on
the
lower
portion
of
the front
panel.
B.
Welding
Cables
If
welding
cables
were
not
ordered with
this
unit,
the
steps
listed
should
be
followed
to
ensure
the
best
welding
performance:
1.
It
is
recommended
that
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.
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
quate
size.
2.
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.
3.
Do
not
use
damaged
or
frayed
cables.
4.
Use
correct
lugs
on
the
weld
cables
to
connect
them
to
the
weld
output
terminals.
5.
Ensure
that
all
connections
are
clean
and
tight.
OM-267
Page
7
I
I
61
I
I
IQI
0
9J
r
~u
161
o
~o
II
II
U
I
I
I
IQu
101
L..J
r--
II
r~
0
101 o
I
I
I I
~
I
I
I I
I
,
I
I
I
I
0
IP\I
IQI
U
L~?J
L_
230
VOLTS
460
VOLTS
10 01
I'
01
10
01
10 01
0
01
10
01
o
10
01
o
01
o
10 61
0
0
0
CAUTION
___________
Ensure
that
the
unit
is
completely
shut
down before
making
any
weld
output
connections.

Table
3-2.
Welding
Cable Size
Welding
Amperes,
DC

Total
Length
Of Cable
(Copper)
In
Weld
Circuit
50 100
150
200 250 300
350
400
100
4 4
2 2 2
1
1/0 1/0
150
2 2 2
1
1/0
2/0
3/0
3/0
200
1 11
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
2-2/0
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
2-4/0
500
4/0 4/0 4/0
2-2/0 2-3/0
2-4/0
500MCM
1000MCM
600
4/0 4/0 2-2/0 2-3/0 2-4/0
500MCM
1000MCM
1000MCM
700
4/0
4/0
2-3/0
2-4/0
500MCM
1000MCM 1000MCM
1000MCM
800
2-2/0 2-2/0 2-3/0 2-4/0
1000MCM
1000MCM
1000MCM
1000MCM
900
2-3/0 2-3/0
2-4/0
500MCM 1000MCM
1000MCM
1000MCM 1000MCM
1000
2-3/0
2-3/0
2-4/0
1000MCM
1000MCM
1000MCM
1000MCM
1250
2-4/0
2-4/0
500MCM 1000MCM
1000MCM 1000MCM
1500 500MCM 500MCM 1000MCM 1000MCM
1000MCM
1750
1000MCM
1000MCM
1000MCM 1000MCM
2000 1000MCM 1000MCM 1000MCM
TA-052
764
NOTE:
A.
50
FEET
OR
LESS.
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 OPEN-
CIRCUIT
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.
When the weld
output
terminals
are
not
bused
together,~
500
amperes
of weld
output
is
available
bet
ween
one
A
Positive and
A
Negative
output
terminals
of
the 1000 models.
Simultaneously,
500
amperes
of
weld
output
is
available
between
one
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.
These
units
are
shipped
with
the
bus
bar
in
place.
t~.tUJlIsI~
If
the
positive
output
terminal
of
one
sec
tion of
this
power
source
is
connected
to
the
negative
output
terminal
of
the
other
section,
two
times the
nor
mal
output voltage
will
exist between the
remaining
two
output
terminals. Consult
applicable
safety
codes.
2.
For 1500V
Models
Up
to
500
amperes
of
dc weld
output
is
available
from
the A
output
terminals.
Up
to 1000
amperes
of dc weld
output
is available
from
the
B
output
terminals.
Before
making
connections
to
the
output
terminals,
select
the
desired
polarity
for
the
specific
application involved,
and
connect
the
weld cables
to
the
positive
(+)
and
negative
(-)
terminals
accordingly.
Although
the
A
por
TA-044 915
tion is
separate
from the
B
portion,
both
may
be used
at
the
same
time and
with
different
polarity
connections if
desired.
DC
Po~iti~e
DC
Ngti~e
DC
Po~,tiv~
DC
Ne~tiv.
'
'''
'' '
'
''
A
B
A
B
A
B
A B
500
AMP
POSITION
1000
AMP
POSITION
079146
1000
Ampere
Models
'
'
'
'
'
'
'
@3 @3
''
A B
A B
A B
A
B
C.
Weld
Output
Connections
1. For
1000
And
1500
Models
150
AMP
POSITION
1500 AMP
POSITION
059
539
1500
Ampere
Models
Figure
3-5.
Weld
Output
Connections
For
1000
And
1500
Models
A
Output
Terminals:
500
Amperes
Available
B
Output
Terminals
1000
Amperes
Available
Figure
3-6.
Weld
Output
Connections
For
1500V
Models
Page
8

SECTION
4
-
OPERATION
Figure
4-1.
Front
Panel
4-1. POWER
CONTROL
SWITCH
(Figure
4-1)
CAUTION
_________
Depressing
the
POWER
CONTROL
STOP
button
does
not
remove
power
from
all
of the
welding
power
source
internal
circuitry.
Completely
ter
minate
all
electrical
power
to
the
we/ding
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
tion.
If
connected
to
a
fuse
box,
remove
the
fuses
and
padlock
the
cover
in
a
closed
position.
If
the
unit/s
con
nected
to
a
circuit
breaker;,
or
other
disconnecting
device without
locking
faculties,
attach
a
red
tag
to
the
device
to
warn
others
that
the
circuit is
being
worked
on.
4-2.
OVERLOAD
PROTECTION
-
Thermostat
TP1,
located
in
the main
transformer,
is wired into the
con
tactor
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
cool before
resuming
operations.
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
caus
ing
the
contactor
to
drop
out
thereby
suspending
all
operations.
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 ciruit
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.
PILOT
LIGHT
-
The
pilot
light
PL1
indicates
when
the
welding
power
source
is
in
a
ready-to-weld
status.
4-4.
METERS
-
The
meters are
provided
to monitor
the
welding operation.
They
are
not
intended
for
exact
TB-079824
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,
etc.).
The
ammeters
will indicate the current
output
of
the
unit.
-_
%%~



~


MODEL
GPS.1000
50 60
70
80
90 100
%
DUTY
CYCLE
B-079809
4-5.
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
continuous
ly.
Figure
4-2
enables
the
operator
to
determine
the
safe
output
of
the
welding
power
source
at
various
duty
cycles.
IMPORTANT
__________
Exceeding
the
indicated
duty
cycle
will
cause
overheating
and
thereby
damage
to
the
welding
power
source.
Circuit
Voltmeter
A
Start
And
Stop
Buttons
B
A
B
DC
Positive*
DC
Negative
*1000
Models
Illustrated
RATED
OUTPUT
2000
Lu
4
1500
C,
z
0
~1
Lu
1000
GPS.1500
40
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.
Figure
4-2.
Duty
Cycle
Chart
OM-267
PageS

SECTION
5-
MAINTENANCE
CAUTION
_________
Depressing
the POWER
CONTROL
STOP
button
does
not
remove
power
from
all of
the
welding
power
source
internal
circuitry.
Completely
ter
minate
all
electrical
power
to
the
we/ding
power
source
by
employing
machinery
lockout
procedures
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit. If
the
we/ding
power
source
is
connected
to
a
disconnect
switch,
padlock
the switch
in
an
open
posi
tion.
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
faculties,
attach
a
red
tag
to
the
device
to
warn
others
that
the circuit
is
being
worked
on.
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
no
attention
should
be
required.
5-2. 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.
The
welding
power
source
outer
enclosure should be
removed and
a
clean,
dry
air
stream
or vacuum
suction
should
be
used for
this
cleaning
operation.
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
would
completely
shut
down.
SECTION
6
-
TROUBLESHOOTING
CAUTION
___________
Hazardous
voltages
are
present
on
the in
ternal
circuitry
of
the
welding
power
source
as
long
as
power
is connected
to the unit. 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.
It is assumed that
proper
installation has
been
made,
ac
cording
to
Section
3
of
this
manual,
and that
the
welding
power
source
has been
functioning
properly
until this
trouble
developed.
Use
this chart
in
conjunction
with
the circuit
diagram
while
performing troubleshooting
procedures.
If the
trouble is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized Service Sta
tion should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers recommendations
should be
strictly
followed.
TROUBLE PROBABLE
CAUSE
REMEDY
No
output.
Thermostat
TPI
open.
Allow
unit
a
cooling period.
Replace
defective
TP1.
Fan
motor switch
FMS
open.
is
Hold START button
in
mOmentarily.
Fan
motor
rpm
is
too
slow due
to
voltage.
low
input
Replace
defective
fan
motor
FM.
Replace
defective
FMS.
Circuit
breaker CB
open.
Reset
CB.
Replace
defective
CB.
Fuse Fl
is
blown.
*Replace
defective
Fl.
*lf
it
becomes
necessary
to
replace
any
fuse
in the
welding
power
source,
ensure
that
a
fuse of
the
proper
size is
used.
Page
10

L
Circuit
Diagram
No.
8-080
675
Figure
6-1.
Circuit
Diagram
For
1000
Models
~GRD.
POSITIVE
Circuit
Diagram
No.
CB-902
388-lA
Figure
6-2.
Circuit
Diagram
For
1500
Models
OM-267
Page
11

460V.
L
ONL V
L
PRO.
B-046
910
500 AMPERE
1000
AMPERE
NEGATIVE
SECTION
POSITIVE NEGATIVE
SECTION
POSITIVE
Circuit
Diagram
No.
B-046
910-A
Figure
6-3.
Circuit
Diagram
For
1500V
Models
Page
~2

September
1980
FORM:
OM-267B
PARTS
LIST
Effective
With
Serial No.
JA372254
MODEL
GPS-1000
GPS-1
500
G PS-i
500V

Figure
A

Left Side View
13

15

16
OM-267
Page
1

Figure
A
Left Side
View
Quantity
Model
1000
I
1500
1
1500V
1
059
572
2
059
592
3
T2 036
630
4
W
048597
048
599
*048
600
Wi
048
731
Fl
*604
259
012 638
SR1,ll
079827
VS1,2
024471
Dl
-6,
11-16
Cl
-6,
11-16
7
SR1,l1
Ci
-6,
11-16
Dl
-6,
11-16
7
SR1
Cl -6
Dl
-6
vs
i
7
SR11
Cll-16
Dll-16
8
Vl,2
9
Ai,2
9
Al,2
9 Al
9 A2
10
PB1
11 PL1
Shunt
Shunt
Shunt
COVER,
opening
-
exit
cable
PANEL,
rear
TRANSFORMER,
control
100
VA
115-230/460
CONTACTOR,
3
pole
110-120/208-240
(consisting
of)
COIL,
115/230
volts
KIT,
point
-
contact
INTERLOCK,
contactor
-
normally
open
FUSE,
cartridge
30
amp
600 volts
HOLDER,
fuse
-
cartridge
30
amp
600 volts
RECTIFIER,
silicon
diode
(consisting
of)
SUPPRESSOR,
1 uf
2.7 ohm

DIODE,
rectifier
275
amp
250
volts
straight polarity
RECTIFIER,
silicon
diode
(consisting
of)

CAPACITOR,
ceramic
0.01
uf
500 volts
DIODE,
rectifier
275
amp
250
volts
straight
polarity
SUPPRESSOR,
1 uf 2.7 ohm
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,
amp
dc
50
MV
0-800 scale
METER,
amp
dc 50
mv0.1K
scale
METER,
amp
dc 50 MV 0-800 scale
METER,
amp
dc 50 MV 0-1 .5K scale
SWITCH,
push
button
-
start
-
stop
60
amp
110
volts
BULB,
incandescent
-
slide
base
120
volts
HOUSING,
light
-
slide base 125
volts
LENS,
light
-
red clear
CIRCUIT
BREAKER,
manual
reset
2P
5
amp
240
volts
ac
BAFFLE,
air
-
top
rectifier
BRACKET,
mounting
-
terminal board
SHUNT,
meter
50 MV
800
amp
SHUNT,
meter
50
MV
1000
amp
SHUNT,
meter
50 MV
1500
amp
TERMINAL
ASSEMBLY,
power
-
output
(consisting
of)
NUT,
brass-hex
jam
5/8-11
NUT,
brass
-
hex full
5/8-1
1
TERMINAL
BOARD
STUD,
brass
5/8-1
1
x
3
WASHER,
flat
-
SAE
5/8
WASHER,
lock
-
external tooth
5/8
BUS
BAR
1
6
12
6
18
2 2
2
1 1
1
1
1 1
1
1
1 1
1 1
1 1
2
1
1.
1 1
16
16
16
8 8
8
2
2 2
8 8 8
8 8
8
8
8 8
4
4
4
*Recommended
Spare
Parts.
BE
SURE TO PROVIDE MODEL
AND
SERIAL NUMBERS WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Part
No.
Mkgs.
No.
Description
5
6
7
037
157
.
DIODE,
rectifier 275
amp
250
volts
straight polarity
031 689
.
CAPACITOR,
ceramic 0.01 uf 500 volts dc
059 685
RECTIFIER,
silicon
diode
(consisting
of)
031
689
.
CAPACITOR,
ceramic 0.01 uf
500
volts dc
11
1
1
1
1
1
1
1
1
1
1
1 1
1
1
11
2
6
18
1
1
1
1
1
1
1
1
1
2
1
12
6
2
2
1
1
1
1
1
1
1
037
157
049 782
031
689
037
156
024
471
049
781
031 689
037
156
025
638
059 118
059 120
059 118
044
104
011 636
*027 629
027 631
027 628
034
945
059 563
059 616
079 388
030 635
030 605
059
567
601 841
601
842
059 566
038 909
602
249
602 219
038
032
CB
12
13
14
15
15
15
16
OM-267
Page
2

Figure
B

Right
Side
View
31
32
2\28
30
k41*
Page
3