Miller Electric SQUAREWAVE 1000 Owner'S Manual Download Page 4 | Manualshive

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Summary of Contents for SQUAREWAVE 1000

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

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...F 9 SECTION 3 DEFINITIONS 11 3 1 Symbol Definitions 11 SECTION 4 INSTALLATION 11 4 1 Specifications 11 4 2 Duty Cycle And Overheating 12 4 3 Volt Ampere Curves 13 4 4 Selecting A Location 14 4 5 Dimen...

Page 4: ......

Page 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Page 6: ...they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the wo...

Page 7: ...ns D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cover...

Page 8: ...ork NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 910...

Page 9: ...ource lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes...

Page 10: ...protection Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La project...

Page 11: ...pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteille...

Page 12: ...provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel...

Page 13: ...Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid ra...

Page 14: ...OM 2223 Page 10 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 15: ...3 Phase Power Source With AC DC Output Temperature Ventilating And Air Circulating Fan Increase IP Degree Of Protection Air Carbon Arc Cutting CAC A Shielding Metal Arc Welding SMAW Gas Metal Arc Wel...

Page 16: ...heating 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 NOTICE Exceeding duty cycle can damage...

Page 17: ...lt Ampere Curves Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown va_curve1 4 95 ST 199 986 A ST 190 97...

Page 18: ...de of unit 3 Rating Label Use rating label to determine input power needs Label located under front access door 4 Line Disconnect Device Locate unit near correct input pow er supply Special installati...

Page 19: ...30 in 762 mm Including lift eye B 23 in 584 mm B C C 38 in 966 mm Including strain relief F D 35 in 889 mm F G H 4 Holes E 1 1 4 in 32 mm 4 Holes F 21 1 8 in 537 mm D G 1 1 8 in 29 mm D H 7 16 in 11 m...

Page 20: ...ntary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volts ac portion of RC8 1T and RC9 from overload CB2 protects 24 volts ac portion of RC8 and 1T from overload Press button to reset p...

Page 21: ...age sense wire is 12 gauge or larger For better performance for most Sub Arc SAW applica tions make connections to the Submerged Arc weld output terminal Polarity For DCEP Reverse Polarity connect we...

Page 22: ...ote 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 Set desired preset voltag...

Page 23: ...se leads detect arc voltage ac curately Best starts arcs and most reliable results BAD Sense lead is affected by weld current Due to voltage drops across work piece arc voltage may be low causing need...

Page 24: ...need for deviation from standard procedures BAD Current flow from lead affects trail sense Current flow from trail affects lead sense Neither sense lead picks up the correct work voltage causing star...

Page 25: ...0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 900 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 4 4 0 4 4 0 1000 2 2 0 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 1250 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 Weld cable size AWG is bas...

Page 26: ...eceptacle 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 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain R...

Page 27: ...uit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and incl...

Page 28: ...d Current Sensor Optional Connect green or green yellow grounding conductor to welding power source ground ing terminal first If unit is equipped with op tional ground current sensor route ground ing...

Page 29: ...position digital meters will read 0 zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant Voltage posit...

Page 30: ...unreadable labels Clean and tighten weld terminals Repair or replace cracked weld cable 6 Months Blow out or vacuum inside During heavy service clean monthly OR 6 2 Fuse F1 Ref 802 295 Turn Off power...

Page 31: ...d tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 minimum weld output Check posi...

Page 32: ...OM 2223 Page 28 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 33: ...OM 2223 Page 29 236 682 A...

Page 34: ...30 SECTION 8 PARTS LIST 802 296 D Figure 8 1 Main Assembly Hardware is common and not available unless listed 33 25 32 31 27 28 1 3 4 5 6 2 4 5 26 13 14 15 3 25 22 24 23 1 19 12 8 37 17 11 18 16 10 7...

Page 35: ...40 750 SWITCH reed 1 24 W 193 473 CONTACTOR size 3 1 2 3P 24VAC 1 25 217 136 LABEL warning electric shock 2 26 193 462 BRACKET contactor mount 1 27 163 359 BASE 1 28 T1 218 414 TRANSFORMER pwr main 23...

Page 36: ...LG5 152 249 CONNECTOR SOCKETS 1 PLG16 158 719 CONNECTOR SOCKETS 1 3 CR3 052 964 RELAY encl 24VDC DPDT 1 4 CR5 006 393 RELAY encl 24VAC DPDT 1 5 CB1 2 093 995 SUPPLEMENTARY PROTECTOR man reset 1P 15A 2...

Page 37: ...IT CARD ASSY display w program 1 PLG10 153 501 CONNECTOR SOCKETS 1 PLG11 148 439 CONNECTOR SOCKETS 1 27 CR2 116 592 RELAY encl 24VDC 3PDT 1 28 192 174 STAND OFF 4 29 193 704 PANEL front upper 1 NAMEPL...

Page 38: ...ckey puck 6 6 191 247 HEAT SINK rectifier snowflake3 000 3 7 191 246 CLAMP thyristor rectifier 8 187 3 PLG1 158 720 CONNECTOR SOCKETS 1 TP3 192 731 THERMOSTAT rectifier 1 TP6 168 894 THERMOSTAT rectif...

Page 39: ...97 459 RESISTOR WW fxd 375W 20 ohm for units w o low ocv 1 8 FM 032 605 MOTOR 1 4HP 230VAC 1625RPM 50 60Hz 1 9 183 167 CONNECTOR clamp cable 2 000 1 802 298 C Hardware is common and not available unle...

Page 40: ...Notes...

Page 41: ...Notes...

Page 42: ...Notes...

Page 43: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 44: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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