Miller Electric Subarc DC 1000 Owner's Manual
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Miller Electric Subarc DC 1000 Owner's Manual

Miller Electric Subarc DC 1000 Owner's Manual

Arc welding power source ce and non-ce
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Subarc DC 1000/1250
CE And Non-CE
OM-229 253F
2010−11
Processes
Multiprocess Welding
Description
Arc Welding Power Source
File: Multiprocess

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Summary of Contents for Miller Electric Subarc DC 1000

  • Page 1 OM-229 253F 2010−11 Processes Multiprocess Welding Description Arc Welding Power Source Subarc DC 1000/1250 CE And Non-CE File: Multiprocess Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • 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 _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • 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. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-229 253 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. General Precautionary Label Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

  • Page 16: Input Connection Label

    3-2. Input Connection Label Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine. Consult rating label for input power requirements, and check power available at the...

  • Page 17: Symbol Definitions

    3-5. 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 Rated No-Load Rated Supply Percent Circuit Breaker...

  • Page 18: Section 4 − 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 19: Volt-Ampere Curves

    4-4. Volt-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. A. CC Mode B. CV Mode AMPERES AMPERES va_curve1 − 4/95 − ST-199 986-A / ST-190 973 4-5.

  • Page 20: Selecting A Location

    4-6. 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. Line Disconnect Device Locate unit near correct input pow- er supply. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 21: Dimensions And Weights

    4-7. Dimensions And Weights Dimensions 30 in. (762 mm) Including lift eye 23 in. (584 mm) 38 in. (966 mm) Including strain relief 35 in. (889 mm) 1-1/4 in. (32 mm) 4 Holes 21-1/8 in. (537 mm) 1-1/8 in. (29 mm) 7/16 in.

  • Page 22: 115 Vac Receptacle, Supplementary Protectors, And Weld Output Terminals

    4-9. 115 VAC Receptacle, Supplementary Protectors, And Weld Output Terminals Turn power before connecting to receptacle, or weld output terminals. 115 V 15 A AC Receptacle Power is shared between RC9, Re- mote 14 receptacle RC8 and termi- nal strip 1T (see Section 4-13). Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects 115 volts AC portion...

  • Page 23: Basic Sub Arc (Saw) Welding

    4-10. Basic Sub Arc (SAW) Welding Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, gun, welding wire, weld cables, remote voltage sense leads, and flux system for the desired application. A.
  • Page 24 B. Control Settings For Sub Arc (SAW) Welding Set switches as shown for remote con- trol. 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 voltage on Sub Arc controller.
  • Page 25 C. 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 26 D. 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 27: Weld Output Terminals And Selecting Cable Sizes

    4-11. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 28: Remote 14 Receptacle And Terminal Strip 1T Information

    4-12. Remote 14 Receptacle And Terminal Strip 1T Information Socket Terminal Information 24 volts AC. Protected by circuit breaker CB2. 24 VOLTS AC Contact closure to A completes 24 volts AC contactor control circuit. Command reference; 0 to +10 volts DC (CC), +10 volts DC (CV). Remote control circuit common.

  • Page 29: Connecting Remote Control

    4-13. Connecting Remote Control Turn off power before con- necting to receptacle. Remote 14 Receptacle 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. Terminal Strip 1T Remote Control Cord Strain Relief (Customer...

  • Page 30: Electrical Service Guide

    4-14. Electrical Service Guide Elec Serv 2009−08 A. 1000 Ampere Rated Welding Output Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Input Voltage (V) Input Amperes (A) At Rated Output...

  • Page 31: Placing Jumper Links

    4-15. Placing Jumper Links Disconnect and lockout/tag- out input power before installing or moving jumper links. Check input voltage available at site. Jumper Link Label Check label − only one is on unit. Jumper Link Move jumper links to match input voltage, and label on unit.

  • Page 32: Connecting Input Power

    4-16. Connecting Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. = GND/PE Earth Ground Make input power connections to the welding power source first.

  • Page 33: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls 229 210-A Arc Force (Dig) Control Amperage/Voltage Adjustment Control Remote Amperage/Voltage Control Switch When Process Selector switch is in the Control increases SMAW short-circuit Constant Current position, turn control For front panel control, place switch in amperage which allows the operator to use clockwise to increase amperage.

  • Page 34: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect and lockout/tagout input power before per- forming maintenance or troubleshooting procedures. Every Months l Unreadable Labels n l Weld Cables ~ Weld Terminals Every Months ~ Inside Unit (monthly dur- ing heavy service) 6-2.

  • Page 35: Troubleshooting

    6-3. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect device in On position (see Section 4-16). inoperative; pilot light PL1 off. Check for open line fuse(s), and replace if open (see Section 4-16). Check for proper input power connections (see Section 4-16). Check for proper jumper link position (see Section 4-16).

  • Page 36: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-229 253 Page 32...
  • Page 37 236 683-A OM-229 253 Page 33...

  • Page 38: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 296-D Figure 8-1. Main Assembly OM-229 253 Page 34...
  • Page 39 Item Dia. Part Mkgs. Description Quantity 8-1. Main Assembly ..... +179 432 PANEL, side ..........
  • Page 40 Hardware is common and not available unless listed. 802 297 Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) Item Dia. Part Mkgs. Description Quantity Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) ..... . 159 863 ELECTRONICS BOX .
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Panel, Front w/Components (Figure 8-1 Item 32) (Continued) ..... . 070 371 BLANK, snap-in nyl 1.093/1.125mtg hole .
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 8-3. Rectifier, SCR Main (Figure 8-1 Item 33) ..C7-12 ..048 420 CAPACITOR, cer disc .01uf 1000VDC ......
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-4. Panel, Rear w/Components (Figure 8-1 Item 21) ....132 101 CHAMBER, plenum 14 in/motor mount .
  • Page 44 Notes...
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...
  • 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. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Miller Electric Mfg. Co. 2010−01...

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