Miller Summit Arc 1000 Owner'S Manual Download

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ORIGINAL INSTRUCTIONS

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PRINTED IN USA



2012 Miller Electric Mfg. Co.

2012

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Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters

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USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

For International Locations Visit

www.MillerWelds.com

Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor

Address

City

State

Zip

Please complete and 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 Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

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.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

Summary of Contents for Summit Arc 1000

Page 1: ...Processes OM 2221 186 183AD 2012 11 Processes Description Submerged SAW Welding Arc Welding Power Source Summit Arc 1000 1250 Visit our website at www MillerWelds com File Submerged SAW CE And Non CE ...

Page 2: ...ontinue 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 the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ...able Sizes 16 3 9 Selecting AC or DC Output 17 3 10 Terminal Strip TE3 and Remote 14 Receptacle RC7 Information 17 3 11 Basic Sub Arc SAW Welding 18 3 12 Connecting Remote Control 21 3 13 115 Volts AC Receptacle And Circuit Breaker 460 And 575 Volt Input Models 22 3 14 230 Volts AC Receptacle And Circuit Breakers 400 Volt Input Models 22 3 15 Electrical Service Guide 23 3 16 Connecting Input Power...

Page 4: ...estriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources IEC 60974 10 2007 Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied processes w...

Page 5: ...ds when in 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 order presented 1 a semiautomaticDC 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 volt...

Page 6: ...ms or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 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 work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D ...

Page 7: ...G PARTS can injure D Keep away from moving parts such as fans 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 and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labe...

Page 8: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pi...

Page 9: ...lectrique à courant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ...

Page 10: ...ne et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le contact a...

Page 11: ...Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonctionnemen...

Page 12: ...des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l installa tion D L utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l installation D Si le FCC signale des interférences arrêter immédiatement l ap pareil D Effectuer régulièrement le contrôle et l entretien de l installation D Maintenir soigne...

Page 13: ...Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333...

Page 14: ...OM 2221 Page 10 ...

Page 15: ...tage I2 Rated Welding Current Protective Earth Ground I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current 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 Welding GMAW 3 2 WEEE Label For Products Sold Within The EU Do not discard p...

Page 16: ...se in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated disturbances IEC TS 61000 3 4 may be used to guide the parties concerned by the installation of arc welding equipment with an input current above 75 Amps in a ...

Page 17: ...e amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 181 560 Continuous Welding 100 Duty Cycle At 1000 Amperes 4 5 Volt Ampere Curves va_curve1 4 95 189 242 189 240 189 243 189 241 Volt amperecurves show minimum and maximum voltage and amper age output capabilities of unit Curves of other ...

Page 18: ...ons 1225 lb 540 kg A B C E Front D Weight Height 44 in 1118 mm Width 27 1 4 in 692 mm Depth 46 in 1168 mm A 1 7 8 in 48 mm B 44 1 8 in 1120 mm C 11 16 in 17 mm D 26 1 16 in 662 mm E 4 holes 21 32 in 6 5 mm dia Includes lifting eye handles hardware etc ...

Page 19: ...forks beyond opposite side of unit 3 Rating Label 4 Plate Label Use rating or plate label to deter mine input power needs 5 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 OR 1 Movement 2 Location 18 in 5 460 mm 18 in 460 mm 3 4 ...

Page 20: ...a 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 600 3 0 95 4 0 120 2 ea 2 0 2x7...

Page 21: ...C 1 2 Tools Needed 3 8 11 16 7 8 in 4 10 Terminal Strip TE3 and Remote 14 Receptacle RC7 Information Socket on RC7 Terminal on TE3 Information 24 VOLTS AC A A 24 volts 12 amperes AC Protected by circuit breaker CB2 B B Contact closure to A completes 24 volts AC contactor control circuit REMOTE OUTPUT CONTROL C C Command reference 10 volts DC D D Remote control circuit common E E 0 to 10 volts DC i...

Page 22: ...e sense leads in all applications Suggested size for remote volt age sense wire is 12 gauge or larger For better performance for most Sub Arc SAW applica tions make connections to the high inductance weld output terminal 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 Strip 1T Terminal P ...

Page 23: ...nse 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 for deviation from standard procedures Work Clamp Remote Voltage Sense Leads Work Clamp Welding Power Source Welding Power Source Remote Voltage Sense Leads ...

Page 24: ...g 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 starting and welding arc instability Lead Trail Lead Trail Lead Trail Trail Trail Lead Lead Work Clamp Work Clamp Trail Lead Work Clamp Work Clamp Trail Lead Trail Lead Trail Lead Welding Power Source We...

Page 25: ...ptacle If plug does not fit wire cord to terminal strip TE3 see Section 4 10 for terminal information 3 Terminal Strip TE3 Mounted Inside Access Area 4 Lead Being Connected To TE3 5 Securing Screw Strip 3 8 in 10 mm insulation off end of lead insert end into proper location on TE3 and tighten appli cable securing screw Close and secure access door 2 OR OR A J B K I C L N H D M G E F 1 3 4 5 3 Tool...

Page 26: ...r CB1 CB1 protects 115 volts AC recep tacle and 115 volts AC portion of terminal strip TE3 and Remote 14 receptacle from overload 1 Ref 175 086 Ref 801 882 B 2 4 14 230 Volts AC Receptacle And Circuit Breakers 400 Volt Input Models 1 230 V 16 A AC Receptacle 2 Circuit Breaker CB1 CB1 protects the 115 volts AC por tion of terminal strip TE3 and Re mote 14 receptacle from overload 3 Circuit Breaker ...

Page 27: ...5 200 200 175 175 150 Min Input Conductor Size In AWG 4 1 0 1 0 1 0 2 1 3 Max Recommended Input Conductor Length In Feet Meters 398 121 441 134 474 145 490 149 482 147 548 167 Min Grounding Conductor Size In AWG 4 4 6 6 6 6 6 Reference 2011 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparab...

Page 28: ... Page 24 4 16 Connecting Input Power input_2 3 96 Ref 144 221 Ref 801 883 B 3 8 in Tools Needed 7 16 in 3 16 in 1 2 3 5 L3 W L1 U L2 V 7 10 8 4 9 6 GND PE Earth Ground 4 6 Input Contactor 3 GND PE Earth Ground ...

Page 29: ...en screws 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor 5 Reed Switch Ground 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 grounding conductor through reed switch two times and connect to grounding terminal 6 Welding Po...

Page 30: ...ed voltage is approxi mately 53 volts swap the input con ductor connections to L1 and L3 on the primary input contactor of unit B If the measured voltage is approxi mately 46 volts swap L1 and L2 on the primary input contactor of unit B The meter will then read either approximately 53 volts or approxi mately 26 volts If the meter reads approximately 53 volts swap L1 and L3 If the meter reads appro...

Page 31: ... be able to carry the weld output of the individual welding power source see Section 4 8 Do not exceed duty cycle of welding power sources If there are any questions re garding this procedure con tact the factory before con necting units For DC electrode positive Connect the proper size and number of weld output cables see Section 4 8 to one of the welding power source electrode terminals Connect ...

Page 32: ... Part 1910 Subpart Q addresses at be ginning of manual Do not handle or come in contact with two live electrodes at the same time Undersized weld cables can cause fire Work cable or electrode cable must be able to carry the weld output of the individual welding power source see Section 4 8 Do not exceed duty cycle of welding power sources If there are any questions regarding this procedure contact...

Page 33: ...put connec tions See ANSI Z49 1 and OSHA Title 29 Chapter XVII Part 1910 Sub part Q addresses at beginning of manual Do not handle or come in contact with two live electrodes at the same time Undersized weld cables can cause fire Work cable or electrode cable must be able to carry the weld output of the individual welding power source see Section 4 8 Do not exceed duty cycle of welding power sourc...

Page 34: ...Being Connected To TE4 3 Securing Screw Strip 3 8 in 10 mm insulation off end of lead insert end into proper location on TE4 and tighten appli cable securing screw Close and secure access door Connect plug as shown in Sec tion 5 5 Tools Needed A B C 1 D E Terminal Strip TE4 Connections For Running Multiple AC Arcs AC Waveforms Waveform 1 Waveform 2 Phase Shift Connections from first to second weld...

Page 35: ... con tact the factory before con necting units Remove top cover 1 Front Panel 2 Control Board PC1 PC1 is mounted on inside of control panel 3 Receptacle RC4 PC1 arrives from the factory with a 66 34 plug Plugs are labeled accordingly Always keep disconnected plug for future use Reinstall circuit card cover and top cover Tools Needed 3 8 in PC1 Viewed From Rear Of Unit Ref 801 982 A 2 3 1 2 ...

Page 36: ...E3 or Remote 14 receptacle and place switch in Remote position Remote control provides full range of unit output re gardless of A V Adjust control setting 3 Pilot Light 4 Power Push Button Switch The fan motor is thermostatically controlled and only runs when cooling is needed 5 High Temperature Shutdown Light Lights if welding power source overheats 6 A V Amperage Voltage Adjustment Control Use c...

Page 37: ... 14 receptacle and place switch in Remote position Remote control provides full range of unit output re gardless of A V Adjust control setting 3 Pilot Light 4 Power Push Button Switch The fan motor is thermostatically controlled and only runs when cooling is needed 5 High Temperature Shutdown Light Lights if welding power source overheats 6 A V Amperage Voltage Adjustment Control Use control to se...

Page 38: ...Weld Terminals Every 6 Months Blow out inside 7 2 Fuses F1 And F2 Ref 801 883 B Turn Off welding power source and disconnect input power before checking fuse Fuses F1 and F2 protect the 115 volt AC winding of transformer T2 If fuse F1 or F2 opens the welding power source shuts down Remove top cover from unit to ac cess fuses 1 Fuse F1 Check F1 and replace if needed using a fuse of the same rating ...

Page 39: ...ee Section 4 16 No weld output pilot light On Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 4 Have Factory Authorized Service Agent check control board PC1 Erratic or improper weld output Use proper size and type of weld cable see Section 4 8 Clean and tighten all weld connections When using multiple units make sure all units connected with ter...

Page 40: ...OM 2221 Page 36 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram For 460 And 575 VAC Input Models ...

Page 41: ...OM 2221 Page 37 224 360 B ...

Page 42: ...OM 2221 Page 38 Figure 8 2 Circuit Diagram For 400 VAC Input Models ...

Page 43: ...OM 2221 Page 39 224 361 B ...

Page 44: ...2221 Page 40 SECTION 9 PARTS LIST 801 981 B Hardware is common and not available unless listed 15 14 13 17 18 16 19 21 22 5 23 25 26 27 31 28 29 27 30 24 1 33 32 5 6 12 11 1 2 3 4 Figure 9 1 Main Assembly ...

Page 45: ...an On Demand 1 19 184 344 Stop Cover 1 026 627 Gasket Lift Eye 1 20 T2 094 237 Transformer KVA 1 2 115 230 460 460 Model 1 20 T2 096 145 Transformer KVA 1 2 115 230 575 575 Model 1 20 T2 185 359 Transformer KVA 1 2 115 220 400 400 50 60Hz Model 1 21 184 342 Lift Eye 1 22 184 341 Bar Cross Lift Eye 2 23 184 345 Bracket Rectifier 1 24 SR1 213 441 Rectifier Scr Main Consisting Of 1 25 026 947 Stand O...

Page 46: ...e 42 Hardware is common and not available unless listed 801 982 D 30 32 37 35 36 33 34 31 1 2 5 3 6 8 9 4 10 25 29 28 5 27 26 24 23 20 12 15 13 16 18 17 14 19 22 15 21 11 39 39 38 7 Figure 9 2 Front Panel Assembly ...

Page 47: ...Output Consisting Of 1 15 601 841 Nut Brs Hex Jam 625 11 16 16 038 032 Bus Bar Neg And Pos Sec 4 208 935 Terminal Hammer On 3 0 4 0 1 17 601 842 Nut Brs Hex Full 625 11 8 18 059 566 Terminal Board Pwr Output 2 19 038 909 Stud Brs 625 11 X 3 000 8 20 602 249 Washer Flat Stl Sae 625 8 21 602 219 Washer Lock Stl External Tooth 625 8 22 059 983 Bus Bar Jumper Secondary 2 23 188 514 Bracket Mtg Term As...

Page 48: ...2 207 Plate Adapter Power Cord 1 8 FM 032 605 Motor Cap Perm Sp 1 4Hp 230 VAC 1625RPM 1 9 CR3 188 184 Relay Encl 24 120VAC DPDT 5A 120VAC 9Pin Flange 1 Hardware is common and not available unless listed 801 983 A 6 8 7 5 4 3 2 1 9 Figure 9 3 Rear Panel Assembly When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original pe...

Page 49: ...Notes ...

Page 50: ...TM 216 869 Page 46 Dynasty 350 700 Maxstar 350 700 Notes ...

Page 51: ...Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limi...

Page 52: ...h 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 Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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