Miller Electric Summit Arc 1000/1250 Owner's Manual
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Miller Electric Summit Arc 1000/1250 Owner's Manual

Miller Electric Summit Arc 1000/1250 Owner's Manual

Arc welding power source ce and non-ce
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OM-2221
186 183AC
2011−03
Processes
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source
Summit Arc 1000/1250
CE And Non-CE
File: Submerged (SAW)
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-2221 186 183AC 2011−03 Processes Processes Submerged (SAW) Welding Description Arc Welding Power Source Summit Arc 1000/1250  CE And Non-CE File: Submerged (SAW) Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001 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.

  • Page 4: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • 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 injure. 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 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 Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-2221 Page 10...

  • Page 15: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 16: Duty Cycle And Overheating

    3-4. Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 100% Duty Cycle At 1000 Amperes If unit overheats, high temperature shutdown light turns On, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 17: Dimensions And Weight

    3-6. 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.

  • Page 18: Weee Label (For Products Sold Within The Eu)

    3-8. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycling office or your local distributor for further information.

  • Page 19: Weld Output Terminals And Selecting Cable Sizes

    3-10. Weld Output Terminals and Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 20: Selecting Ac Or Dc Output

    3-11. Selecting AC or DC Output 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 Ï...

  • Page 21: Basic Sub Arc (Saw) Welding

    Polarity: For DCEP (Reverse Polarity), connect weld cables and voltage sense leads as shown. For DCEN (Straight Polarity), reverse weld cables and voltage sense leads. Flux System Summit Arc 1000/1250 Electrode Work Flux Valve HDC Controller 14-Pin Welding Power Source...
  • Page 22 B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required) Remote Voltage Sense Leads Welding Power Sense lead is affected by weld Source current. Due to voltage drops across work piece, arc voltage may be low, causing need for deviation from standard procedures.
  • Page 23 C. Sensing Leads Placement Guidelines For Multiple Arcs Remote Voltage Lead Sense Leads Welding Power Source Current flow from lead affects trail sense. Current flow from trail affects lead Remote Voltage sense. Sense Leads Neither sense lead picks up the Lead Trail correct work voltage, causing...

  • Page 24: Connecting Remote Control

    3-14. Connecting Remote Control 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 3-12 terminal...

  • Page 25: 115 Volts Ac Receptacle And Circuit Breaker (460 And 575 Volt Input Models)

    3-15. 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 3-12).

  • Page 26: Electrical Service Guide

    3-17. 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. Three-Phase, 50/60 Hz Three-Phase, 60 Hz Input Voltage (V)

  • Page 27: Connecting Input Power

    3-18. Connecting Input Power Installation must meet all National and Local Codes − have only qualified per- sons make this installation. Disconnect and lockout/tagout input power before connecting input conduc- tors from unit. Make input power connections to the welding power source first. Always connect green or green/yellow = GND/PE Earth Ground conductor to supply grounding terminal...

  • Page 28: Matching Primary Lines L1, L2, And L3 When Using Multiple Ac Units

    3-19. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units Turn Off welding power source and disconnect input Set on AC Volts Scale power before opening ac- cess door. This test must be performed on the Meter Polarity Does Not Matter units that will be interconnected us- ing the synchronizing terminal strip TE4.

  • Page 29: Section 4 − Making Weld Output Connections

    SECTION 4 − MAKING WELD OUTPUT CONNECTIONS 4-1. Work And Electrode Cable Connections For Single DC or AC Arcs Turn welding power source and disconnect input power before opening access door. High weld output current haz- ard! Remove all metal jewelry, such as rings and watches, and be careful with tools near output terminals.

  • Page 30: Using Multiple Units: Dc Lead Arc, One Or More Ac Trailing

    4-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing Turn Off welding power source and dis- connect input power before opening access door. High weld output current hazard! Re- move all metal jewelry, such as rings and watches, and be careful with tools near output terminals.

  • Page 31: Using Multiple Units: Two Or More Ac Arcs

    4-3. Using Multiple Units: Two or More AC Arcs Turn Off welding power source and disconnect input power before opening ac- cess door. High weld output current hazard! Remove all metal jewelry, such as rings and watches, and be careful with tools near output terminals.

  • Page 32: Using Ac Arcs Terminal Strip Te4 Connections

    4-4. Using AC Arcs Terminal Strip TE4 Connections Turn Off welding power source and disconnect input power before opening ac- cess door. DC output units do not re- quire synchronization with Tools Needed: AC output units. If there are any questions re- garding this procedure, con- tact the factory before con- necting units.

  • Page 33: Control Board Pc1 Connections

    4-5. Control Board PC1 Connections Turn Off welding power source and disconnect input power before following this procedure. If there are any questions re- garding this procedure, con- tact the factory before con- necting units. Remove top cover. Front Panel Control Board PC1 PC1 is mounted on inside of control panel.

  • Page 34: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Front Panel Controls (Non-CE Models) Output Control Switch For remote control, connect remote device to A/V (Amperage/Voltage) Adjustment terminal strip TE3 or Remote 14 receptacle, Control For weld output, place switch in On position. and place switch in Remote position. Remote For remote control of output, make connec- Use control to select weld voltage or amper- control provides full range of unit output re-...

  • Page 35: Front Panel Controls (Ce Models)

    5-2. Front Panel Controls (CE Models) Output Control Switch For remote control, connect remote device to A/V (Amperage/Voltage) Adjustment terminal strip TE3 or Remote 14 receptacle, Control For weld output, place switch in On position. and place switch in Remote position. Remote For remote control of output, make connec- Use control to select weld voltage or amper- control provides full range of unit output re-...

  • Page 36: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect input power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ...

  • Page 37: Access Area Supplementary Protectors

    6-3. Access Area Supplementary Protectors Turn Off welding power source and disconnect input power before checking cir- cuit breakers. Supplementary Protector CB2 CB2 protects the 24 VAC portion of terminal strip TE3 and the Remote 14 receptacle. Supplementary Protector CB3 CB3 protects the 42 VAC portion of terminal strip TE3.

  • Page 38: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS Figure 7.1. Circuit Diagram For 460 And 575 VAC Input Models OM-2221 Page 34...
  • Page 39 224 360-B OM-2221 Page 35...
  • Page 40 Figure 7.2. Circuit Diagram For 400 VAC Input Models OM-2221 Page 36...
  • Page 41 224 361-B OM-2221 Page 37...

  • Page 42: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 801 981-B Figure 8-1. Main Assembly OM-2221 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... 071 624 Panel, Side ............
  • Page 44 Hardware is common and not available unless listed. 801 982-D Figure 8-2. Front Panel Assembly OM-2221 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Front Panel Assembly (Figure 8-1 Item 32) ....245 321 Cover, Receptacle Weatherproof Duplex RCPT ..... .
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 8-3. Rear Panel Assembly (Figure 8-1 Item 15) ..059 266 Relay, Encl 120 VAC DPDT 10A/120 VAC ......
  • Page 47 LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...

  • Page 48: Options And Accessories

    Contact the Delivering Carrier to: 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.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co. 2011−01...

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