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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

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at

Customers

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and

expense.

Upon

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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

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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~

t

?t,

J~

~

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