Miller 1020- User Manual

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Resistance Spot Weld...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Resistance Spot Welding Hazards

OM-744 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING spotom _nd_11/99 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T...

Page 6 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards

OM-744 Page 2 The tong tips, tongs, and linkages move duringoperation. MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points. D Do not put hands between tips. D Keep all guards and panels securely in place. D OSHA and/or local codes may require additional guardi...

Page 7 - SECTION 2 – INSTALLATION; Specifications

OM-744 Page 3 SECTION 2 – INSTALLATION 2-1. Specifications Input Work Rated Output Amperes Input Voltage Work Capacity Rated Output Rated Output Amperes At Listed Tong Length Open- ATT Models Voltage 50/60 Hz AC 1-Phase Input Amps Capacity Combined Thickness Mild Steel At Listed Duty Cycle* 6 in (15...

Page 8 - Moving The Spot Welder

OM-744 Page 4 2-3. Moving The Spot Welder ST-161 850 / ST-162 632 1 Rating Label Locate unit near correct inputpower supply. 2 Skid Place unit on skid and secure withstraps. 2 1 1

Page 9 - Installing Or Cleaning Tongs

OM-744 Page 5 2-4. Installing Or Cleaning Tongs Y Turn off unit and disconnectinput power. . Be sure tong ends are cleanand not corroded before instal-ling. Clean tongs with fine steelwool. Bottom Tong Installation: 1 Spatter Guard 2 Insulating Strip Check to see that insulating strip isnot cracked....

Page 12 - Air Connections

OM-744 Page 8 2-9. Air Connections REV DATE X X . ST-112 848-C 1 Air Hoses (CustomerSupplied) Obtain two hoses of correct size,type, and length. Air-In fittings oncontrol boxes have 5/8-18 left-handthreads. 2 Air Filter Connect one hose to air supply andother end to input fitting on filter. 3 Regula...

Page 14 - SECTION 3 – OPERATION; Controls

OM-744 Page 10 SECTION 3 – OPERATION 3-1. Controls ST-801 934 / Ref. ST-801 525 / Ref. ST-112 846-B 1 Weld Time Control Select spot weld time from 0 to 9.99seconds. Weld time begins at the end of the squeezetime cycle. 2 Weld Switch Use control to check tong pressure andalignment without weld ampera...

Page 15 - SECTION 4 – MAINTENANCE AND TROUBLESHOOTING; Maintenance; Months

OM-744 Page 11 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Maintenance Y Disconnect power before maintaining. . During heavy service, maintain monthly. 3 Months Oil Unit Replace Damaged Or Unreadable Labels Inspect Tips 4-2. Overload Protection Ref. ST-112 847-D / Ref. ST-800 185-A Y Turn Off u...

Page 16 - Installing Or Dressing Tips

OM-744 Page 12 4-3. Installing Or Dressing Tips ST-801 437 1 Tip 2 Telescoping Tube Removal: Tips have a Morse Taper and apress fit. . Use a vice grip pliers to rotateand loosen tips. Once loose,pull tips straight out. Y Do not move tips from side toside when removing or tele-scoping tube will snap ...

Page 17 - Troubleshooting

OM-744 Page 13 4-4. Troubleshooting Trouble Remedy No weld output; pilot light Off. Check line fuses, and replace if necessary (see Section 2-7). Check fuse(s) F1 and/or F2, and replace if necessary (see Section 4-2). Turn On Power Switch S1. Check for proper coolant supply pressure (see Section 2-4...

Page 18 - SECTION 5 – ELECTRICAL DIAGRAMS

OM-744 Page 14 SECTION 5 – ELECTRICAL DIAGRAMS SA-128 142 Figure 5-1. Circuit Diagram For Portable Models SA-128 145 Figure 5-2. Circuit Diagram For Stationary Models

Page 20 - Notes

Page 21 - SECTION 6 – PARTS LIST

OM-744 Page 17 SECTION 6 – PARTS LIST Fig 6-2 Fig 6-6 Fig 6-3 Fig 6-4 & 6-5 ST-112 663-F . Hardware is common andnot available unless listed. Figure 6-1. Main Assembly Figure 6-1. Main Assembly Description Quantity Part No. Model PSW- SSW- 2020ATT 1020ATT 1040ATT 2020ATT2040ATT 176 977 FILTER, l...

Page 35 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 36 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...

Table of Contents:

Summary

Other Miller Models