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Miller Summit Arc 1000 Owner's Manual

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OM-2221
186 183B
March 2002
Processes
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source
Summit Arc 1000
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Summit Arc 1000

  • Page 1 OM-2221 186 183B March 2002 Processes Processes Submerged (SAW) Welding Description Arc Welding Power Source  Summit Arc 1000 Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......The following terms are used interchangeably 1-1.
  • 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 Summit ArcE 1000...

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION NOTE With 60 Hz input power, the ac weld output of this unit is 10 Hz. With 50 Hz input, the ac weld output is 8.33 Hz. 2-1. Specifications RMS Amps Input at Rated Load Output, 3-Phase at NEMA Load Voltages and Class I Rating Voltage...

  • Page 14: Volt-Ampere Curves

    2-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode DC Output AC Output B. CV Mode AC Output DC Output va_curve1 4/95 –...

  • Page 15: Dimensions And Weight

    2-4. Dimensions And Weight Dimensions Height* 44 in (1118 mm) Width* 27-1/4 in (692 mm) Weight Depth* 46 in (1168 mm) 1225 lb (540 kg) 1-7/8 in (48 mm) 44-1/8 in (1120 mm) 11/16 in (17 mm) 26-1/16 in (662 mm) Front 4 holes: 21/32 in (6.5 mm) dia...

  • Page 16: Manufacturer's Rating Label For Ce Products

    2-6. Manufacturer’s Rating Label For CE Products 2-7. Selecting a Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. Rating Label Plate Label Use rating or plate label to deter- mine input power needs.

  • Page 17: Weld Output Terminals And Selecting Cable Sizes

    2-8. Weld Output Terminals and Selecting Cable Sizes NOTE In the table below, when multiple numbers are indicated separated by a hyphen, the number to the left of the hyphen indicates how many cables are to be used, and the number to the right indicates the size of the cable to be used. For example, 3-3/0 indicates that 3 cables of 3/0 gauge need to be used for electrode and work connections.

  • Page 18: Selecting Ac Or Dc Output

    2-9. Selecting AC or DC Output Y Turn Off welding power source and disconnect input power before relinking unit. Remove top of unit. Ï Ï Ï AC/DC Output Selection Label (Located Inside Unit) Ï Ï Ï Ï Ï Ï Ï Ï...

  • Page 19: Connecting Remote Control

    2-11. Connecting Remote Control Y Turn Off welding power source and disconnect input power before opening ac- cess door. Access Door Remote 14 Receptacle (Mounted Inside Access Area) Connect remote control to Remote 14 receptacle. If plug does not fit, wire cord to terminal strip TE3 (see Section 2-10...

  • Page 20: 115 Volts Ac Receptacle And Circuit Breaker (460 And 575 Volt Input Models)

    2-12. 115 Volts AC Receptacle And Circuit Breaker (460 And 575 Volt Input Models) 115 V 12 A AC Receptacle Power is shared between the du- plex receptacle and the 115 volt output connections at terminal strip TE3 and the Remote 14 receptacle (see Section 2-10).

  • Page 21: Electrical Service Guide

    2-14. Electrical Service Guide Three-Phase, Three-Phase, 60 Hz 50/60 Hz Input Voltage 380/400/415 Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 382 (116) 417 (127) 575 (175)

  • Page 22: Matching Primary Lines L1, L2, And L3 When Using Multiple Units

    2-16. Matching Primary Lines L1, L2, And L3 When Using Multiple Units Y Turn Off welding power source and disconnect input power before opening ac- Set on AC Volts Scale cess door. This test must be performed on the units that will be interconnected us- Meter Polarity Does Not Matter ing the synchronizing terminal strip TE4.

  • Page 23: Section 3 - Making Weld Output Connections

    SECTION 3 – MAKING WELD OUTPUT CONNECTIONS 3-1. Work And Electrode Cable Connections For Single DC or AC Arcs Y Turn Off welding power Y If there are any questions regarding source and disconnect input this procedure, contact the factory be- power before opening ac- fore connecting units.

  • Page 24: Using Multiple Units: Dc Lead Arc, One Or More Ac Trailing Arcs With Separate Electrodes

    3-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing Arcs With Separate Electrodes Y Turn Off welding power Y If there are any questions regarding source and disconnect input this procedure, contact the factory be- power before opening ac- fore connecting units.

  • Page 25: Using Multiple Units: Two Or More Ac Arcs With Separate Electrodes

    3-3. Using Multiple Units: Two or More AC Arcs With Separate Electrodes Y Turn Off welding power Y If there are any questions regarding source and disconnect input this procedure, contact the factory be- power before opening ac- fore connecting units. cess door.

  • Page 26: Using Multiple Units: Parallel Dc Output Connections

    3-4. Using Multiple Units: Parallel DC Output Connections Y Turn Off welding power Y If there are any questions regarding source and disconnect input this procedure, contact the factory be- power before opening ac- fore connecting units. cess door. Y ELECTRIC SHOCK can kill. To use multiple units in parallel, make connections as shown.

  • Page 27: Using Multiple Units: Parallel Ac Output Connections

    3-5. Using Multiple Units: Parallel AC Output Connections Y Turn Off welding power Y If there are any questions regarding source and disconnect input this procedure, contact the factory be- power before opening ac- fore connecting units. cess door. Y Always test for correct phas- Y ELECTRIC SHOCK can kill.

  • Page 28: Synchronizing Outputs For Parallel Ac Arcs

    3-6. Synchronizing Outputs For Parallel AC Arcs Y Turn Off welding power Y If there are any questions regarding this procedure, source and disconnect input contact the factory before connecting units. power before opening ac- cess door. Terminal Strip TE4 This procedure allows the ac out- puts of two or more units to be syn- chronized...

  • Page 29: Using Non-Parallel Ac Arcs With A 60° Phase Shift - Terminal Strip Te4 Connections

    3-7. Using Non-Parallel AC Arcs With A 605 Phase Shift - Terminal Strip TE4 Connections NOTE When using the 605 ac arc phase shift feature, be sure to follow Section 3-7 and Section 3-8 to set up the welding power sources properly. Y Turn Off welding power Y If there are any questions regarding this procedure, source and disconnect input...

  • Page 30: Control Board Pc1 Connections For Non-Parallel Ac Arcs

    3-8. Control Board PC1 Connections For Non-Parallel AC Arcs With 605 Phase Shift Or Parallel Synchronized (05 Phase Shift) AC Arcs NOTE When using the 605 ac arc phase shift feature, be sure to follow Section 3-7 and Section 3-8 to set up the welding power sources properly. Y Turn Off welding power source and disconnect input power before following this...

  • Page 31: Testing Ac Output Units For Correct Phasing Prior To Parallel Operation

    3-9. Testing AC Output Units For Correct Phasing Prior to Parallel Operation Y Turn Off welding power Y If there are any questions regarding this procedure, sources and disconnect in- put power before opening contact the factory before connecting units. access door.

  • Page 32: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Front Panel Controls (Non-CE Models) Output Control Switch For remote control, connect remote device to High Temperature Shutdown Light terminal strip TE3 or Remote 14 receptacle, For weld output, place switch in On position. Lights if welding power source overheats. and place switch in Remote position.

  • Page 33: Front Panel Controls (Ce Models)

    4-2. Front Panel Controls (CE Models) Output Control Switch For remote control, connect remote device to High Temperature Shutdown Light terminal strip TE3 or Remote 14 receptacle, For weld output, place switch in On position. Lights if welding power source overheats. and place switch in Remote position.

  • Page 34: Section 5 - Maintenance And Troubleshooting

    SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Maintain more often Y Disconnect input power during severe conditions. before maintaining. 3 Months Replace damaged Replace Repair or cracked or unreadable replace torch body. labels. cracked cables. Repair replace cracked cables and cords.

  • Page 35: Access Area Circuit Breakers

    5-3. Access Area Circuit Breakers Y Turn Off welding power source and disconnect input power before checking cir- cuit breakers. Circuit Breaker CB2 CB2 protects the 24 VAC portion of terminal strip TE3 and the Remote 14 receptacle. Circuit Breaker CB3 CB3 protects the 42 VAC portion of terminal strip TE3.

  • Page 36: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS 193 775-A Figure 6-1. Circuit Diagram For 460 And 575 VAC Input Models OM-2221 Page 32...
  • Page 37 188 378-E Figure 6-2. Circuit Diagram For 400 VAC Input Models OM-2221 Page 33...

  • Page 38: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 801 981-A Figure 7-1. Main Assembly OM-2221 Page 34...
  • Page 39 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ... 071 624 PANEL, side ............
  • Page 40 Hardware is common and not available unless listed. SD-801 982-A Figure 7-2. Front Panel Assembly OM-2221 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Front Panel Assembly (Figure 7-1 Item 32) ....038 805 COVER, receptacle weatherproof ........
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 7-3. Rear Panel Assembly (Figure 7-1 Item 15) ..059 266 RELAY, encl 120 VAC DPDT 10A/120 VAC ......
  • Page 43 Notes OM-2221 Page 39...
  • Page 44 Notes OM-2221 Page 40...
  • Page 47 Effective January 1, 2001 (Equipment with a serial number preface of “LB” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
  • Page 48 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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