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

Miller Electric Dimension 1000 Owner's Manual

Arc welding power source
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Dimension 1000
OM-2223
190 969AC
2007−11
Processes
Multiprocess Welding
Description
Arc Welding Power Source
File: Multiprocess

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Summary of Contents for Miller Electric Dimension 1000

  • Page 1 Visit our website at www.MillerWelds.com Dimension 1000 OM-2223 190 969AC 2007−11 Processes Multiprocess Welding Description Arc Welding Power Source File: Multiprocess...
  • 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 specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.

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

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 OM-2223 Page 2 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding 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 compounds, chemicals known to the State of California to cause cancer and birth defects or other...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
  • Page 10 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 CHAUDES peuvent provoquer des brûlures graves.

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

    ACCUMULATIONS risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller 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 médicaux.

  • Page 12: Proposition Californienne 65 Avertissements

    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.

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, 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 Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
  • Page 14 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2223 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Amperage Alternating Current (AC) Output Submerged Arc Welding (SAW) Percent Conventional Load Voltage Maximum Effective 1eff Supply Current Increase Gas Metal Arc Welding GMAW) SECTION 4 − INSTALLATION 4-1. Specifications Rated Welding Amperage/Voltage Model Output Output...

  • Page 16: Duty Cycle And Overheating

    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.

  • 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 Use rating label to determine input power needs.

  • Page 19: Dimensions And Weights

    4-5. Dimensions And Weights Front 4 Holes 4 Holes 800 453-A / 801 530 Dimensions Dimensions 30 in (762 mm) Including lift eye 23 in (584 mm) 38 in (966 mm) Including strain relief 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...

  • Page 20: Tipping

    4-6. Tipping 4-7. 115 VAC Receptacle, Supplementary Protectors, And Weld Output Terminals OM-2223 Page 16 Do not move or operate unit where it could tip. Turn power before connecting to receptacle, or weld output terminals. 115 V 15 A AC Receptacle Power is shared between RC9, Re- mote 14 receptacle RC8 and termi- nal strip 1T (see Section 4-11).

  • Page 21: Basic Sub Arc (Saw) Welding

    A. Basic Sub Arc (SAW) Equipment Connections Remote Remote 24 VAC 115 VAC Contactor Voltage Remote Remote Control Contactor Contactor Dimension 1000/1250 Submerged Remote Power On/Off Sense S-162 895-B 14-Pin Welding Power Source Control Cord From Terminal Strip 1T Terminal P From Terminal Strip...
  • Page 22 B. Control Settings For Sub Arc (SAW) Welding OM-2223 Page 18 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.
  • Page 23 C. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required) Remote Voltage Sense Leads Remote Voltage Sense Leads Welding Power Source Work Clamp Welding Power Source Work Clamp Sense lead is affected by weld current. Due to voltage drops across work piece, arc voltage may be low, causing need for deviation from standard procedures.
  • Page 24 D. Sensing Leads Placement Guidelines For Multiple Arcs Remote Voltage Sense Leads Lead Trail Remote Voltage Sense Leads Lead Trail Work Clamp Trail Remote Voltage Sense Leads Lead Trail OM-2223 Page 20 Lead Welding Power Source Remote Voltage Sense Leads Trail Welding Power Source...

  • Page 25: Selecting Cable Sizes

    4-9. Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference. To 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.

  • Page 26: Connecting Remote Control

    4-11. Connecting Remote Control C L N OM-2223 Page 22 Turn off power before con- necting to receptacle. Remote 14 Receptacle RC8 Connect remote control to RC8. If plug does not fit, wire cord to terminal strip 1T. Turn Off power before open- ing terminal strip cover.

  • Page 27: Electrical Service Guide

    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. Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes...

  • Page 28: Connecting Input Power

    4-14. Connecting Input Power Tools Needed: 3/8 in 3/8 in 11/16 in OM-2223 Page 24 = GND/PE Earth Ground IMPORTANT Input Terminal Board L1 (U) L2 (V) L3 (W) GND/ PE Earth Ground Installation must meet all National and Local Codes − have only quali- fied persons make this installation.

  • Page 29: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls 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.

  • Page 30: 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 26 Disconnect and lockout/tagout input power before per- forming maintenance or troubleshooting procedures.

  • Page 31: Troubleshooting

    6-3. Troubleshooting Trouble No weld output; unit completely Place line disconnect device in On position (see Section 4-14). inoperative; pilot light PL1 off. 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 position (see Section 4-14).

  • Page 32: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-2223 Page 28...
  • Page 33 236 682-A OM-2223 Page 29...

  • Page 34: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 296-D Figure 8-1. Main Assembly OM-2223 Page 30...
  • Page 35 Item Dia. Part Mkgs..... . +179 432 ..... . 179 431 .
  • Page 36 Hardware is common and not available unless listed. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) Item Dia. Part Mkgs. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) ..... . 159 863 .
  • Page 37 Item Dia. Part Mkgs. Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) (Continued) ..... . 070 371 ..
  • Page 38 Item Dia. Part Mkgs..C7-12 ..048 420 ....176 168 ..
  • Page 39 Item Dia. Part Mkgs....132 101 ....605 799 .
  • Page 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 44: 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. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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