Miller Summit Arc 1000 Owner's Manual
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Miller Summit Arc 1000 Owner's Manual

Miller Summit Arc 1000 Owner's Manual

Ce and non-ce
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OM-2221
186 183AD
2012−11
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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Summary of Contents for Miller Summit Arc 1000

  • Page 1 OM-2221 186 183AD 2012−11 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 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

    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 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • 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. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • 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- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-2221 Page 10...

  • Page 15: Symbol Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Some symbols are found only on CE products. Direct Current Amperage Voltage Hertz (DC) Alternating Current Panel/Local Line Connection Three Phase (AC) Output Voltage Input Submerged Arc Read Operator’s Remote Duty Cycle Welding (SAW) Manual Circuit Breaker Rated No-Load...

  • Page 16: Section 3 − Installation

    SECTION 4 − INSTALLATION 4-1. 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 17: Duty Cycle And Overheating

    4-4. 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 18: Dimensions And Weight

    4-6. 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 19: Selecting A Location

    4-7. 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 20: Weld Output Terminals And Selecting Cable Sizes

    **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. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-G 2009−08 OM-2221 Page 16...

  • Page 21: Selecting Ac Or Dc Output

    4-9. 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 22: 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 23 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 24 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 25: Connecting Remote Control

    4-12. 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 4-10 terminal...

  • Page 26: 115 Volts Ac Receptacle And Circuit Breaker (460 And 575 Volt Input Models)

    4-13. 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 4-10).

  • Page 27: Electrical Service Guide

    4-15. 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 circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 28: Connecting Input Power

    4-16. Connecting Input Power = GND/PE Earth Ground L3 (W) L1 (U) L2 (V) Input Contactor GND/ PE Earth Ground Tools Needed: 7/16 in. 3/8 in. 3/16 in. input_2 3/96 - Ref. 144 221 / Ref. 801 883-B OM-2221 Page 24...
  • Page 29 4-16. Connecting 3-Phase Input Power (Continued) Supplied Cord) Connect input conductors L1 (U), L2 (V) and Installation must meet all National L3 (W) to welding power source line and Local Codes − have only qualified Select size and length of conductors using terminals.

  • Page 30: Matching Primary Lines L1, L2, And L3 When Using Multiple Ac Units

    4-17. 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 31: Section 4 − Making Weld Output Connections

    SECTION 5 − MAKING WELD OUTPUT CONNECTIONS 5-1. 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 32: Using Multiple Units: Dc Lead Arc, One Or More Ac Trailing

    5-2. 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 33: Using Multiple Units: Two Or More Ac Arcs

    5-3. 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 34: Using Ac Arcs Terminal Strip Te4 Connections

    5-4. 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 35: Control Board Pc1 Connections

    5-5. 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 36: Section 5 − Operation

    SECTION 6 − OPERATION 6-1. 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 37: Front Panel Controls (Ce Models)

    6-2. 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 38: Section 6 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. 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 39: Access Area Supplementary Protectors

    7-3. 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 40: Section 7 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8.1. Circuit Diagram For 460 And 575 VAC Input Models OM-2221 Page 36...
  • Page 41 224 360-B OM-2221 Page 37...
  • Page 42 Figure 8.2. Circuit Diagram For 400 VAC Input Models OM-2221 Page 38...
  • Page 43 224 361-B OM-2221 Page 39...

  • Page 44: Section 8 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 801 981-B Figure 9-1. Main Assembly OM-2221 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ... 071 624 Panel, Side ............
  • Page 46 Hardware is common and not available unless listed. 801 982-D Figure 9-2. Front Panel Assembly OM-2221 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Front Panel Assembly (Figure 9-1 Item 32) ....245 321 Cover, Receptacle Weatherproof Duplex RCPT ..... .
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 9-3. Rear Panel Assembly (Figure 9-1 Item 15) ..059 266 Relay, Encl 120 VAC DPDT 10A/120 VAC ......
  • Page 49 Notes...
  • Page 50 Notes TM-216 869 Page 46 Dynasty 350/700, Maxstar 350/700...
  • Page 51 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...

  • Page 52: 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 2012 Miller Electric Mfg. Co. 2012−01...

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