October 1981 FORM: OM-267C Effective With Serial No. JB522183 MODEL GPS-1000 G PS-i 500A GPS-1 500V OWN ERS MANUAL HilliER ~ \.~ MILLER ELECTRIC MFG. CO. 718 5. BOUNDS ST. P.O. Box 1079 APPLETON WI 54912 USA ADDITIONAL COPY PRICE 55 CENTS NWSA CODE NO. 4579 PRINTED IN U.S.A.
~r.. P Lc t~P L~J LIMITED This warranty supersedes all previous MILLER warranties and is ex clusive with no other guarantees or warranties expressed or implied. LIMITED ( cessories ( ~ WARRANTY-Subject to the terms and conditions As hereof, Miller Electric Mt g. Co., Appleton, Wisconsin warrants to its Distributor/Dealer that all new and unused Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
ERRATA SHEET After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. AMENDMENT TO SECTION 4 - OPERATION Add Section 4-6. VOLT-AMPERE CURVE The volt-ampere Add Figure curve (Figure 4-3 on this Errata Sheet) shows the maximum voltage and amperage output capabilities of the welding power source. 4-3.
Amend Figure 6-2. Circuit Diagram For 1500A Models 460V ONLY 000 AMPERE NEGATIVE SECTION POSITIVE Circuit Diagram No. B-088 038 Figure OM-267C Page B 6-2. Circuit Diagram For 1500A Models Effective With Serial No.
Amend Figure 6-3. Circuit Diagram For 1500V Models 4~OV. O~lt. Y 000 AMPERE AMPERE SECTON SCO NEGATIVE SECTION POSITIVE 8 A Circuit Figure 6-3. Circuit Diagram POSITIVE Diagram No. 8-088 039 For 1500V Models Effective With Serial No. JC646118 Effective With Serial No. JC646118 Quantity Item Or Dia. Part Replaced Page No. Mkgs. No.
TABLE OF CONTENTS Page Section No. SECTION 1 1 1 1 1 - - - - No. SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1. Introduction 1 2. General Precautions 1 3. Arc 4. Standards Booklet Index SECTION 2 2- 1. Welding INTRODUCTION 5 General 2- 2. Receiving-Handling 2- 3. Description 2-4. Safety SECTION 3 3 4 5 5 5 INSTALLATION 3-1. Location 6 3- 2. Electrical Input Connections 6 3 - 3. Weld Output Connections SECTION 4 4- 1.
1-SAFETY RULES FOR OPERATION OF ARC SECTION 1-1. of concentrations harmful INTRODUCTION POWER SOURCE WELDING Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and unwite. Let the experience of others teach you. We learn at experience. by tained. The reason are explain. It wear local Adequate each person in the an area air-supplied respirator. be used.
thorough steam or caustic cleaning (or a washing, depending on the combustibles solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recom mended in A6.0. Waterfilling just below working level may substitute for inerting.
Use and operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor safe pressure charts (available from your supplier( for efficient, recommended pressure settings on regulators. level. for leaks Check Brush with soap after. pressurization solution (capful first on regularly there of Ivory Liquidt or and Viewing the weld. Provide face shields for looking directly at she weld. equivalent per gallon of waser(. Bubbles indicate leak.
2. Electrode Holders Do power circuit or change polarity while welding. emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. not open If, Fully insulated electrode holders should holders with protruding screws. be used. Do NOT in an use 3. Leaving equipment unattended. Always shut OFF and dis all power to equipment. Connectors connect Fully insulated lock-type welding cable lengths. 4.
SECTION 2 INTRODUCTION - Input At Rated Load Output Max. Rated Welding Current Amperes 100% Duty Cycle Model 60 Hz. Three-Phase Open- ~ Amperes At Circuit 230V Voltage 460V Weight kva 575V Dimensions kw 41-1/8 in. (1045 mm) Width 27-1/4 in. (692 mm) Depth -46 in. (1168 mm) Height 1000 1000 @76 Volts 85 224 112 89 90 85 Height 1500 @76 Volts 85 330 165 131 132 - 896 lbs. 986 lbs. (406 kg) (447 kg) 1068 lbs. 1158 lbs. (484 kg) )525 kg) - .
1~.tU1lIs1~ Connect welding power the three-phase the input conductors to the making connections to source before power supply. The input conductors should be covered with an in sulating material which conforms to local electrical stan dards. Table 3-1 is provided only as a guide for selecting the proper size input conductors and fuses. / Table 3-1.
operated voltages from various line The voltages. various i0 from which this unit may be the nameplate and on the input operated are stated on voltage label. The input voltage jumper links are positioned for the highest of the voltages stated on the nameplate. If the welding power source is to be operated from a line voltage which is lower than the highest voltage for which the unit was designed, the jumper links will have to be moved to the proper positions before operating the unit.
Table 3-2. Welding Welding Cable Size Total Amperes.
SECTION 4 Pilot OPERATION Circuit breaker CB protects the welding power source excessive secondary current draw. Current transformer CT1 and CT2, located in the secondary of Circuit Breaker - from Light Ammeter A Ammeter B the main transformer, ..Voltmeter Voltmeter A B sense overloading draw. Should ing the contactor operations.
SECTION 5- MAINTENANCE CAUTION: Depressing the POWER CONTROL STOP button does not remove power from all of the power source internal circuitry. Completely ter minate all electrical power to the welding power source welding by employing machinery lockout procedures before attempting any inspection or work on the inside of the unit. If the welding power source is connected to a disconnect switch, padlock the switch in an open posi tion.
B POSITIVE Circuit Diagram No. B-082 509 Figure 6-1. Circuit Diagram For 1000 Models 460V ONLY 500 NEGATIVE fl~ORQF y,)~ 000 POSITIVE NEGATIVE A*,PFPF sFcrft)~ POSITIVE A Circuit Diagram No. B-083 538-A Figure 6-2.
O~LV L~ ~RD Circuit Figure 6-3. Circuit Diagram For 1500V Models Page 12 Diagram No.
October 1981 FORM: OM-267C Effective With Serial No.
Figure OM-267 Page 1 A Left Side View
Quantity Item Dia. No. Mkgs.
2\ 28 29 .
/ / Quantity Item D~. Part No. cvlkgs. No. Figure Model 1000 Description Right Side B 27 009 139 28 070 556 Ri 1 030 691 R12 604 288 SR12 083 719 Ci 7 031 640 C18 031 683 29 TEl 059 555 29 TEl 044 098 601 375 038 897 044 099 602 221 1 1 RESISTOR, carbon 1 watt 4700 ohm RESISTOR; WWfixed i0watt2 ohm RECTIFIER, silicon control CAPACITOR, electrolytic 500 uf 200 volts RING, mounting capacitor CAPACITOR,paperoilo.
N N .
