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Miller Electric 1000 manual

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Table of contents for the manual

  • Page 1

    Processes Description Multiprocess W elding Arc Welding Power Source OM-2223 190 969R January 2005 Dimension 1000/1250  V isit our website at www.MillerWelds.com[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    dec_con1 10/95 Declaration of Conformity For European Community (CE) Products This information is provided for units with CE certification (see rating label on unit.) NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Dimension  1000/1250 conf[...]

  • Page 5

    OM-2223 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch Out[...]

  • Page 6

    OM-2223 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z8[...]

  • Page 7

    OM-2223 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-2223 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Weld[...]

  • Page 9

    OM-2223 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signifie « NOT[...]

  • Page 10

    OM-2223 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent ca u- ser des brûlures oculaires et cuta- nées. D Porter u n masque de soudage[...]

  • Page 11

    OM-2223 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surchar[...]

  • Page 12

    OM-2223 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N. W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Pipi[...]

  • Page 13

    OM-2223 Page 9 SECTION 3 − DEFINITIONS 3-1. General Precautionary Label W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric [...]

  • Page 14

    OM-2223 Page 10 3-2. Input Connection Label 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power [...]

  • Page 15

    OM-2223 Page 1 1 3-5. Manufacturer ’ s Rating Label For CE Products . For label location see Section 4-4. 3-6. Symbol Definitions Some symbols are found only on CE products. NOTE A Amperage V V oltage Hz Hertz Direct Current (DC) Alternating Current (AC) Panel/Local Line Connection Three Phase Output On V oltage Input Of f Submerged Arc W elding [...]

  • Page 16

    OM-2223 Page 12 SECTION 4 − INST ALLA TION 4-1. Specifications Model Rated Welding Output Amperage/V oltage Range DC Max OCV−DC Amperes Input at Rated Load Output, 60 Hz, Three-Phase Amperes Input at Rated Load Output, 50 Hz, Three-Phase Output Range DC OCV−DC 230 V 460 V 575 V 380 V 400 V 440 V KV A KW 1000 Amp 1000 A @ 44 V olts DC, 100% 10[...]

  • Page 17

    OM-2223 Page 13 4-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 − 4/95 − ST -199 986-A / ST -190 973 A. CC Mode B. CV Mode[...]

  • Page 18

    OM-2223 Page 14 4-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label (Non CE Models Only) Use rating label to determine input power needs. Label located under front access door . 4 Plate Label (CE Models Only) Label lo[...]

  • Page 19

    OM-2223 Page 15 4-5. Dimensions And W eights Dimensions Dimensions A A 30 in (762 mm) Including lift eye B 23 in (584 mm) B C C 38 in (966 mm) Including strain relief D 35 in (889 mm) F G H E 1-1/4 in (32 mm) 4 Holes F 21-1/8 in (537 mm) G 1-1/8 in (29 mm) D H 7/16 in (1 1 mm) Dia W eight E 800 453-A / 801 530 Front 1000 Amp Models 644 lb (292 kg) [...]

  • Page 20

    OM-2223 Page 16 4-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 4-7. 1 15 V AC Receptacle And Circuit Breakers 3 Ref. 802 295 Y T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9, Re- mote 14 receptacle RC8 and termi- nal strip 1T (see Section 4-10 ). 2 Circuit B[...]

  • Page 21

    OM-2223 Page 17 4-8. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding[...]

  • Page 22

    OM-2223 Page 18 4-10. Connecting Remote Control Ref. 802 295 / Ref. S-0004-A / S-0750 Y T urn off power before con- necting to receptacle. 1 Remote 14 Receptacle RC8 Connect remote control to RC8. If plug does not fit, wire cord to terminal strip 1T . Y T urn Off power before open- ing terminal strip cover . 2 T erminal Strip 1T 3 Remote Control Co[...]

  • Page 23

    OM-2223 Page 19 B. 900 Ampere Rated Welding Output 50 Hz Input V oltage 380 400 440 Input Amperes At Rated Output 101 96 87 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 125 11 0 100 Normal Operating 3 150 150 125 Min Input Conductor Size In A WG 4 233 Max Recommended Input Conductor Length In Feet (Meters) 353 (108) 325 (99) 393 ([...]

  • Page 24

    OM-2223 Page 20 4-13. Connecting Input Power Ref. 800 103-C / Ref. 802 295 3/8 in 3/8 in T ools Nee d e d : Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Y Make input power connections to the[...]

  • Page 25

    OM-2223 Page 21 Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual .[...]

  • Page 26

    OM-2223 Page 22 SECTION 5 − OPERA TION 5-1. Controls 4 1 2 3 7 8 5 6 Dimension 1000 Nameplate Dimension 1250 Nameplate 4 1 2 3 7 8 5 6 207 729[...]

  • Page 27

    OM-2223 Page 23 1 Arc Forc e (Dig) Control Control increases SMAW short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode. Set control at 0 for normal welding amper- age. T urn clockwise to increase short-circuit amperage. 2 Process Selector Switch • CV -Sub-Arc Mode − For SAW (Sub-Arc) app[...]

  • Page 28

    OM-2223 Page 24 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . OR 6-2. Fuse F1 Ref. 802 295 Y T u rn Of[...]

  • Page 29

    OM-2223 Page 25 6-3. T roubleshooting T rouble Remedy No weld output; unit completely inoperative; pilot light PL1 off. Place line disconnect device in On position (see Section 4-13 ). Check for open line fuse(s), and replace if open (see Section 4-13 ). Check for proper input power connections (see Section 4-13 ). Check for proper jumper link posi[...]

  • Page 30

    OM-2223 Page 26 SECTION 7 − ELECTRICAL DIAGRAMS 218 515-A For Primary Circuit Diagram Portion, refer to the Circuit Diagram located inside the wrapper of the welding power source. Figure 7-1. Circuit Diagram for 60 HZ Model[...]

  • Page 31

    OM-2223 Page 27 Figure 7-2. Circuit Diagram for 50 HZ Model 218 516-B For Primary Circuit Diagram Portion, refer to the Circuit Diagram located inside the wrapper of the welding power source.[...]

  • Page 32

    OM-2223 Page 28 SECTION 8 − P ARTS LIST 802 296-B Figure 8-1. Main Assembly . Hardware is common and not available unless listed. 50 Hz Models Only 26 33 24 32 31 27 28 1 3 4 5 6 36 2 4 5 26 13 14 15 3 25 22 24 23 1 19 9 12 8 37 17 11 18 16 10 7 20 21 34[...]

  • Page 33

    OM-2223 Page 29 Description Part No. Dia. Mkgs. Item No. 8-1. Main Assembly Quanti ty 1 +179 432 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 179 431 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-2223 Page 30 802 297 1 2 3 5 6 7 8 9 10 9 11 9 12 13 14 15 16 17 18 19 20 21 22 23 36 25 26 27 28 29 30 31 32 33 34 24 25 4 . Hardware is common and not available unless listed. 35 Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32)[...]

  • Page 35

    OM-2223 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) Quanti ty 1 159 863 ELECTRONICS BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PC1 207 035 CIRCUIT CARD ASSY , control (50Hz) 1 . . . . . . . . . . .[...]

  • Page 36

    OM-2223 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Rectifier , SCR Main (Figure 8-1 Item 33) Quanti ty 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 176 168 BAR, mtg rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 37

    OM-2223 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Panel, Rear w/Components (Figure 8-1 Item 21) Quanti ty 1 132 101 CHAMBER, plenum 14 in/motor mount 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 605 799 BLADE, fan 14 in 5wg 30deg .500 bore CW 1 . . . . . . . . . . . . . . . . .[...]

  • Page 38

    Notes[...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 40

    PRINTED IN USA  2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European Headqua rt ers −[...]