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Miller Electric Dimension 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 969AC 2007 − 11 Dimension 1000 ™ V isit our website at www.MillerWelds.com File: Multiprocess[...]

  • 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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • 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

    [...]

  • Page 5

    OM-2223 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or[...]

  • Page 6

    OM-2223 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor ,[...]

  • 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 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead[...]

  • Page 9

    OM-2223 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bole s ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.[...]

  • Page 10

    OM-2223 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUD[...]

  • Page 11

    OM-2223 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants méd[...]

  • Page 12

    OM-2223 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher des [...]

  • Page 13

    OM-2223 Page 9 2-5. P ri nci pal es n or me s de s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Wel[...]

  • Page 14

    OM-2223 Page 10 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 beginni ng of this manual .[...]

  • Page 15

    OM-2223 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions 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 (SAW) Read Operator’s Manual Remote X Duty Cycle Percent U 0 Rated No-Load V oltage (A verage) U 1 Rated Supply [...]

  • Page 16

    OM-2223 Page 12 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle ca n damage un[...]

  • 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 Use rating label to determine input power needs. Label located under front access door . 4 Line Disconnect Device Locate unit near correct input pow-[...]

  • Page 19

    OM-2223 Page 15 4-5. Dimensions And Weights Dimensions Di mens i ons A A 30 in (762 mm) Including lift eye B 23 in (584 mm) B C C 38 in (966 mm) Including strain relief F D 35 in (889 mm) F G H 4 Holes E 1-1/4 in (32 mm) 4 Holes F 21-1/8 in (537 mm) D 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 64[...]

  • Page 20

    OM-2223 Page 16 4-6. Tipping ! Do not move or operate unit where it could tip. 4-7. 1 15 V AC Receptacle, Supplementary Protectors, And Weld Output T erminals 3 Ref. 802 295 ! T urn Off power before connecting to receptacle, or weld output terminals. 1 1 15 V 15 A AC Receptacle RC9 Power is shared between RC9, Re- mote 14 receptacle RC8 and termi- [...]

  • Page 21

    OM-2223 Page 17 4-8. Basic Sub Arc (SA W) Welding . Customer must supply the following: power source, power source control cable, wire drive assembly , wire drive assembly cable, drive roll s, gun, welding wire, weld cables, remote voltage sense leads, and flux system for the desired application. A. Basic Sub Arc (SA W) Equipment Connections Ref. 8[...]

  • Page 22

    OM-2223 Page 18 B. Control Settings For Sub Arc (SA W) W elding Set switchs as shown for remote control. Turn on welding power source, flux system, wire drive assembly and HDC Sub Arc controller . When Control switch is in Remote position, Adjust control does not function. Set desired preset voltage on Sub Arc controller . Preset voltage is display[...]

  • Page 23

    OM-2223 Page 19 C. Remote V oltage Sensing Leads Placement Guidelines For A Single Arc (Required) Ref. 804 108-A BEST Sense leads are out of the current paths. Sense leads detect arc voltage ac- curately . Best starts, arcs and most reliable results. BAD Sense lead is affected by weld current. Due to voltage drops across work piece, arc voltage may[...]

  • Page 24

    OM-2223 Page 20 D. Sensing Leads Placement Guidelines For Multiple Arcs Ref. 804 108-A BEST Both sense leads are out of the current paths. Both sense leads detect arc volt- age accurately . No voltage drop between lead and trail sense. Best starts, arcs and most reliable results. BETTER Lead sense is only affected by weld current from lead. T rail [...]

  • Page 25

    OM-2223 Page 21 4-9. Selecting Cable Sizes 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 machine is installed and grounded according to this manual. If interference still [...]

  • Page 26

    OM-2223 Page 22 4-1 1. Connecting Remote Control Ref. 802 295 / Ref. S-0004-A / S-0750 ! 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 . ! T urn Off power before open- ing terminal strip cover . 2 T erminal Strip 1T 3 Remote Control C[...]

  • Page 27

    OM-2223 Page 23 4-12. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Input V oltage 230 460 575 Input Amperes At Rated Outpu[...]

  • Page 28

    OM-2223 Page 24 4-14. Connecting Input Power Ref. 800 103-C / Ref. 802 295 3/8 in 3/8 in T ools Needed: ! Installation must meet all National and Local Codes − have only quali- fied persons make this installation. ! Disconnect and lockout/tagout in- put power before connecting input conductors from unit. ! Make input power connections to the weld[...]

  • Page 29

    OM-2223 Page 25 SECTION 5 − OPERA TION 5-1. Controls 229 883-A 4 1 2 3 7 8 5 6 1 Arc Force (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 Proces[...]

  • Page 30

    OM-2223 Page 26 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect and lockout/tagout input power before per- forming maintenance or troubleshooting procedures. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. 6 Months Blow out or vacuum inside. During hea[...]

  • Page 31

    OM-2223 Page 27 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 4-14 ). Check for open line fuse(s), and replace if open (see Section 4-14 ). Check for proper input power connections (see Section 4-14 ). Check for proper jumper link posi[...]

  • Page 32

    OM-2223 Page 28 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

  • Page 33

    OM-2223 Page 29 236 682-A[...]

  • Page 34

    OM-2223 Page 30 SECTION 8 − P ARTS LIST 802 296-D Figure 8-1. Main Assembly . Hardware is common and not available unless listed. 33 25 32 31 27 28 1 3 4 5 6 2 4 5 26 13 14 15 3 25 22 24 23 1 19 12 8 37 17 11 18 16 10 7 20 21 38 9[...]

  • Page 35

    OM-2223 Page 31 Description Part No. Dia. Mkgs. Item No. 8-1. Main Assembly Quantity 1 +179 432 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 179 431 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-2223 Page 32 802 297 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) Description Part No. Dia. Mkgs. Item No. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) Quantit[...]

  • Page 37

    OM-2223 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) (Continued) Quantity 17 070 371 BLANK, snap-in nyl 1.093/1.125mtg hole 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 217 865 LABEL,warning electric shock and reduced air 1 . . . . . . .[...]

  • Page 38

    OM-2223 Page 34 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Rectifier , SCR Main (Figure 8-1 Item 33) Quantity 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 176 168 BAR, mtg rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 39

    OM-2223 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Panel, Rear w/Components (Figure 8-1 Item 21) Quantity 1 132 101 CHAMBER, plenum 14 in/motor mount 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 605 799 BLADE, fan 14 in 5wg 30deg .500 bore CW 1 . . . . . . . . . . . . . . . . . [...]

  • Page 40

    Notes[...]

  • Page 41

    Notes[...]

  • Page 42

    Notes[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 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 expe[...]

  • Page 44

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − [...]