Miller Dimension 1000 Owner's Manual
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Miller Dimension 1000 Owner's Manual

Miller Dimension 1000 Owner's Manual

Arc welding power source
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OM-2223
190 969R
January 2005
Processes
Multiprocess Welding
Description
Arc Welding Power Source
Dimension 1000/1250
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Dimension 1000

  • Page 1 OM-2223 190 969R January 2005 Processes Multiprocess Welding Description Arc Welding Power Source Dimension 1000/1250 Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Dimension...

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch 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. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT 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 «...
  • Page 10 LES RAYONS DE L’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. 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. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour re- garder (voir les normes de sécurité...

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    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 surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding 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 Welding and Cut- ting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. General Precautionary Label Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

  • Page 14: Input Connection Label

    3-2. Input Connection Label 1/96 Í Í Í Í 3-3. Electric Shock And Airflow Label 3-4. Nameplate Safety Symbols OM-2223 Page 10 Í Í Í Í Í Í Í Í Í Í Í Í S-179 290 Warning! Watch Out! There are possible hazards as shown by the symbols.

  • Page 15: Manufacturer's Rating Label For Ce Products

    3-5. Manufacturer’s Rating Label For CE Products 3-6. Symbol Definitions NOTE Some symbols are found only on CE products. Amperage Alternating Current (AC) Output Submerged Arc Welding (SAW) Percent Conventional Load Voltage Maximum Effective 1eff Supply Current Increase Gas Metal Arc Welding GMAW) Voltage Panel/Local...

  • Page 16: Section 4 − Installation

    4-1. Specifications Rated Welding Amperage/Voltage Model Output Output Range DC Range DC 100 − 1250 A In CC 1000 A @ 44 Mode 1000 1000 Volts DC, 100% Volts DC, 100% 10 − 60 V In CV Duty Cycle Mode 100 −...

  • Page 17: Volt-Ampere Curves

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

  • Page 18: Selecting A Location

    4-4. Selecting A Location Movement Location And Airflow 18 in (460 mm) OM-2223 Page 14 (460 mm) Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. Rating Label (Non CE Models Only) Use rating label to determine input...

  • Page 19: Dimensions And Weights

    35 in (889 mm) 1-1/4 in (32 mm) 21-1/8 in (537 mm) 1-1/8 in (29 mm) 7/16 in (11 mm) Dia Weight 1000 Amp Models 644 lb (292 kg) 1250 Amp Models 650 lb (295 kg) OM-2223 Page 15...

  • Page 20: Tipping

    4-6. Tipping 4-7. 115 VAC Receptacle And Circuit Breakers OM-2223 Page 16 Y Be careful when placing or moving unit over uneven surfaces. Y Turn power before connecting to receptacle. 115 V 15 A AC Receptacle Power is shared between RC9, Re- mote 14 receptacle RC8 and termi- nal strip 1T (see Section 4-10).

  • Page 21: Weld Output Terminals And Selecting Cable Sizes

    GTAW (TIG) And SMAW (Stick) applications. SMAW (Stick) applications. 1000 1250 *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm equivalent weld cable sizes.

  • Page 22: Connecting Remote Control

    4-10. Connecting Remote Control C L N 4-11. Electrical Service Guide A. 1000 Ampere Rated Welding Output Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters)

  • Page 23: Placing Jumper Links

    B. 900 Ampere Rated Welding Output Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications.

  • Page 24: Connecting Input Power

    4-13. Connecting Input Power Tools Needed: 3/8 in 3/8 in OM-2223 Page 20 = GND/PE Earth Ground IMPORTANT Input Terminal Board L1 (U) L2 (V) L3 (W) GND/ PE Earth Ground Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation.
  • Page 25 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2223 Page 21...

  • Page 26: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Dimension 1000 Nameplate Dimension 1250 Nameplate 207 729 OM-2223 Page 22...
  • Page 27 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. Turn clockwise to increase short-circuit amperage. Process Selector Switch CV-Sub-Arc Mode −...

  • Page 28: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 3 Months Replace unreadable labels. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 6-2. Fuse F1 Tools Needed: 3/8 in OM-2223 Page 24 Repair or replace cracked weld cable.

  • Page 29: Troubleshooting

    6-3. Troubleshooting Trouble No weld output; unit completely Place line disconnect device in On position (see Section 4-13). inoperative; pilot light PL1 off. 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 position (see Section 4-13).

  • Page 30: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS For Primary Circuit Diagram Portion, refer to the Circuit Diagram located inside the wrapper of the welding power source. 218 515-A Figure 7-1. Circuit Diagram for 60 HZ Model OM-2223 Page 26...
  • Page 31 For Primary Circuit Diagram Portion, refer to the Circuit Diagram located inside the wrapper of the welding power source. Figure 7-2. Circuit Diagram for 50 HZ Model 218 516-B OM-2223 Page 27...

  • Page 32: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 296-B Figure 8-1. Main Assembly OM-2223 Page 28...
  • Page 33 Item Dia. Part Mkgs..... . +179 432 ..... . 179 431 .
  • Page 34 Hardware is common and not available unless listed. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) OM-2223 Page 30 802 297...
  • Page 35 Item Dia. Part Mkgs. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) ..... . 159 863 ..
  • Page 36 Item Dia. Part Mkgs..C7-12 ..048 420 ....176 168 ..
  • Page 37 Item Dia. Part Mkgs....132 101 ....605 799 .
  • Page 38 Notes...
  • Page 39 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 40: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

This manual is also suitable for:

Dimension 1250

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