Miller Summit Arc 1250 Owner's Manual
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Miller Summit Arc 1250 Owner's Manual

Miller Summit Arc 1250 Owner's Manual

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OM-2221
186 183Q
April 2005
Processes
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source
Summit Arc 1000/1250
™
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Summit Arc 1250

  • Page 1 OM-2221 186 183Q April 2005 Processes Processes Submerged (SAW) Welding Description Arc Welding Power Source Summit Arc 1000/1250 ™ 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 ........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 1000/1250...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

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

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 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. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance.
  • Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • 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- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 13: Section 2 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications RMS Amps Input at Rated Load Output, 3-Phase at NEMA Load Voltages and Class I Rating Voltage Voltage Amperage Amperage Max Open- Max. Open- 380/400/415 V 460 V 500 V 575 V AC or DC Range in Range in Circuit...

  • Page 14: Volt-Ampere Curves

    3-3. 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

    3-4. Dimensions And Weight Dimensions Height* 44 in (1118 mm) Width* 27-1/4 in (692 mm) Weight 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

    3-6. Manufacturer’s Rating Label For CE Products 3-7. 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

    3-8. 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

    3-9. 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

    3-11. 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 3-10...

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

    3-12. 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 3-10).

  • Page 21: Electrical Service Guide

    3-14. Electrical Service Guide Three-Phase, 50/60 Hz Three-Phase, 60 Hz Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Operating 3 Min Input Conductor Size In AWG 4 Max Recommended Input Conductor Length In Feet (Me- 398 (121) 441 (134) 474 (145)

  • Page 22: Connecting Input Power

    3-15. Connecting Input Power Y Installation must meet all National and Local Codes − have only qualified per- sons make this installation. See Section 3-16 for information on Y Disconnect and lockout/tagout input testing for proper primary phase power before connecting input conduc- sequence.

  • Page 23: Matching Primary Lines L1, L2, And L3 When Using Multiple Units

    3-16. 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 24: Section 3 − Making Weld Output Connections

    SECTION 4 − MAKING WELD OUTPUT CONNECTIONS 4-1. 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 25: Using Multiple Units: Dc Lead Arc, One Or More Ac Trailing Arcs

    4-2. 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 26: Using Multiple Units: Two Or More Ac Arcs With Separate Electrodes

    4-3. 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 27: Using Multiple Units: Parallel Dc Output Connections

    4-4. 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. To use multiple units in parallel, Y ELECTRIC SHOCK can kill.

  • Page 28: Using Multiple Units: Parallel Ac Output Connections

    4-5. 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 29: Synchronizing Outputs For Parallel Ac Arcs

    4-6. 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 30: Using Non-Parallel Ac Arcs Terminal Strip Te4 Connections

    4-7. Using Non-Parallel AC Arcs Terminal Strip TE4 Connections 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. Y All units must be set up for AC output according to Sec- Tools Needed: tion 3-9.

  • Page 31: Control Board Pc1 Connections For Non-Parallel Ac Arcs Or Parallel Synchronized Ac Arcs

    4-8. Control Board PC1 Connections For Non-Parallel AC Arcs Or Parallel Synchronized AC Arcs Y Turn Off welding power source and disconnect input power before following this procedure. Remove top cover. Y If there are any questions regarding this procedure, Front Panel contact the factory before connecting units.

  • Page 32: Testing Ac Output Units For Correct Phasing Prior To Parallel Operation

    4-9. Testing AC Output Units For Correct Phasing Prior to Parallel Operation Y Turn Off welding power sources and disconnect in- Y If there are any questions regarding this procedure, put power before opening contact the factory before connecting units. access door.

  • Page 33: Section 4 − Operation

    SECTION 5 − OPERATION 5-1. 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 34: Front Panel Controls (Ce Models)

    5-2. 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 35: Section 5 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Maintain more often Y Disconnect input power during severe conditions. before maintaining. 3 Months Replace Replace damaged Repair or cracked or unreadable replace labels. torch body. cracked cables. Repair replace cracked cables and cords.

  • Page 36: Access Area Circuit Breakers

    6-3. 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 37 Notes OM-2221 Page 33...

  • Page 38: Section 6 − Electrical Diagrams

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

  • Page 40: 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 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... 071 624 Panel, Side ............
  • Page 42 Hardware is common and not available unless listed. 801 982-D Figure 8-2. Front Panel Assembly OM-2221 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Front Panel Assembly (Figure 8-1 Item 32) ....038 805 Cover, Receptacle Weatherproof ........
  • Page 44 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 45 Notes OM-2221 Page 41...
  • Page 46 Notes OM-2221 Page 42...
  • Page 47 Effective January 1, 2005 (Equipment with a serial number preface of “LF” 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 Induction Heating Coils and Blankets below, Miller Electric Mfg.
  • Page 48 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. © PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05...

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