Miller SubArc AC/DC Digital 1000 Amp Owner's Manual
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Miller SubArc AC/DC Digital 1000 Amp Owner's Manual

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SubArc AC/DC Digital, 1000 Amp
SubArc AC/DC 1250 Digital
Power Sources
OM-265364N
Processes
Submerged Arc (SAW) Welding
Electroslag (ESW) Welding
Description
Arc Welding Power Source
CE
File: Submerged (SAW)
2020-10

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Summary of Contents for Miller SubArc AC/DC Digital 1000 Amp

  • Page 1 OM-265364N 2020-10 Processes Submerged Arc (SAW) Welding Electroslag (ESW) Welding Description Arc Welding Power Source SubArc AC/DC Digital, 1000 Amp SubArc AC/DC 1250 Digital Power Sources File: Submerged (SAW) For product information, Owner’s Manual translations, and more, visit 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 TABLE OF CONTENTS SECTION 10 − MAINTENANCE AND TROUBLESHOOTING ........10-1.
  • Page 5 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 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number SUBARC AC/DC 1250 DIGITAL 907621 SUBARC AC/DC DIGITAL, 1000 AMP 907620 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822−1:2016, IEC 62822−2:2016 Intended use for occupational use for use by laymen...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 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 8 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 9: Additional Hazards For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 10: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre 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 12 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 14: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste.
  • Page 16 A complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Safe16 2017−04 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012−05 Keep flammables away from welding. Do not weld near flammables. Safe12 2012−05 Use forced ventilation or local exhaust to remove the fumes.

  • Page 17: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Protective Earth Conventional Amperage (Ground) Load Voltage GND/PE 3-Phase Power Primary Current Voltage Source With AC/DC Output Rated Welding Ventilating And Air Hertz Current...

  • Page 18: Section 4 − Specifications

    4-3. Information About Default Weld Parameters And Settings NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 19: Environmental Specifications

    A complete Parts List is available at www.MillerWelds.com 4-7. Environmental Specifications A. IP Rating For All Equipment Covered In This Manual IP Rating IP23 This equipment is designed for outdoor use. IP23 2017−02 B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range 14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C) *Output is derated at temperatures above 104°F (40°C).

  • Page 20: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-8. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, high temperature shutdown light turns On, thermo- stat(s) opens, output stops, and 100% Duty Cycle At 1000 Amperes cooling fan runs.

  • Page 21: Selecting A Location

    A complete Parts List is available at www.MillerWelds.com 5-2. Selecting A Location Movement Do not move or operate unit where it could tip. Special installation may be Location And Airflow required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 22: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-4. Electrical Service Guide A. SubArc AC/DC Digital, 1000 Amp 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 23 A complete Parts List is available at www.MillerWelds.com B. SubArc AC/DC 1250 Digital 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 24: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-5. Connecting Input Power = GND/PE Earth Ground L1 (U) L2 (V) L3 (W) Terminal Block Tools Needed: 7/16 in. 3/8 in. GND/ PE Earth Ground 3/16 in. Ref. Input3 2015-01 /Ref. 247479-C / 803766-C OM-265364 Page 18...
  • Page 25 A complete Parts List is available at www.MillerWelds.com 5-5. Connecting 3-Phase Input Power (Continued) Installation must meet all National Input Power Conductors (Customer Connect input conductors L1 (U), L2 (V) and and Local Codes − have only qualified Supplied Cord) L3 (W) to welding power source line persons make this installation.

  • Page 26: Matching Primary Lines L1, L2, And L3 When Using Multiple Ac Units

    A complete Parts List is available at www.MillerWelds.com 5-6. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units Only qualified persons should install, operate, Set on AC Volts Scale maintain, and repair this unit. This test must be performed on the units that will be interconnected us- ing the test point (TP) terminal strip Meter Polarity Does Not Matter...

  • Page 27: Cable Routing Diagram

    A complete Parts List is available at www.MillerWelds.com 5-7. Cable Routing Diagram SubArc AC/DC Digital Series Welding Power Source Work Sense Lead SubArc Interface Interface Cable Torch Workpiece Weld Cable Work Cable Keep weld and work cables in close proximity to each other. 40 in.

  • Page 28: Section 6 − System Connections

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − SYSTEM CONNECTIONS 6-1. Terminal Strip TE2 and Remote Receptacle RC1 Information For Power Sources Function Socket On RC1 Terminal On TE2 Contact Information Electrical Input Power A, B − 24 VAC.

  • Page 29: Terminal Strip Te1

    A complete Parts List is available at www.MillerWelds.com 6-2. Terminal Strip TE1 Turn off welding power source before opening access door. Access Hole Remove knockout or cover from access hole and install customer supplied strain relief. Route cable connections through the access hole.

  • Page 30: Section 7 − Making Weld Output Connections

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAKING WELD OUTPUT CONNECTIONS 7-1. 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).

  • Page 31: Connecting Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 7-3. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 803778-B Turn off power before connecting to cable terminal and copper bar. Make Weld Cable Terminal weld output terminals. sure that the surfaces of the weld cable Copper Bar terminal and copper bar are clean.

  • Page 32: Basic Subarc (Saw) Welding

    A complete Parts List is available at www.MillerWelds.com 7-5. Basic Subarc (SAW) Welding Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, torch, torch tips, welding wire, weld cables, remote voltage sense leads, and flux system for the desired application. A.
  • Page 33 A complete Parts List is available at www.MillerWelds.com B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required) Electrode Remote Voltage Sense Lead Work Remote Voltage Sense Lead Wire Drive Welding Power Sense lead is affected by weld Source current.
  • Page 34 A complete Parts List is available at www.MillerWelds.com C. Sensing Leads Placement Guidelines For Multiple Arcs Lead Wire Drive Welding Power Source Wire Electrode Remote Volt Drive Sense Leads Work Current flow from lead affects trail sense. Remote Voltage Sense Leads Current flow from trail affects lead Lead Trail...

  • Page 35: Connecting Multiple Units

    A complete Parts List is available at www.MillerWelds.com 7-6. Connecting Multiple Units Turn Off welding power source before making con- nections. NOTICE − This procedure is not for paralleling. Refer to connection be- low for paralleling procedures Tandem Connections: Severe damage to units may occur if units are not correctly connected for parallel operation.

  • Page 36: Section 8 − Power Source Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − POWER SOURCE OPERATION 8-1. Front Panel Controls For CE And Non-CE Models Output Control Switch Turn Off welding power source before Control may be adjusted while welding. Num- connecting remote device. bers on scale are for reference only.

  • Page 37: Section 9 − Plc Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − PLC OPERATION 9-1. Automation Interface Hardware Configuration (PLC Users Only) Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Follow established pro- cedures regarding the install- ation and removal of lockout/ tagout devices.

  • Page 38: Connection To Plc

    A complete Parts List is available at www.MillerWelds.com 9-2. Connection To PLC The automation interface uses an RJ45 connector to communicate MODBUS RTU over RS485. The RJ45 connector is NOT an Ethernet connection! The pin connections are as follows: Table 9-4. Connector Pinout Function RJ45 Pin Circuit...
  • Page 39 A complete Parts List is available at www.MillerWelds.com Table 9-7. Command Flags (MODBUS 101) Flag Name Bitmask Description Output Enable 0x0001 Enable Weld Output Wire Jog Up 0x0002 Feed Wire Up Wire Jog Down 0x0004 Feed Wire Down Flux On 0x0008 Open Flux Valve Motor CW...
  • Page 40 A complete Parts List is available at www.MillerWelds.com Table 9-9. Status Flags (MODBUS 201) Flag Name Bitmask Description Valid Arc 0x0001 A valid arc has been detected. Output On 0x0002 The power source output is on. Run In 0x0004 The power source is in Run In. Weld 0x0008 The power source is in the weld state.
  • Page 41 A complete Parts List is available at www.MillerWelds.com Table 9-10. Weld Mode Look Up Table (continued) Line Input Frequency (Hz) Weld Mode Code Mode Balance 60 Hz Line 50 Hz Line Electrode Positive −− −− 0x8000 80/20 0x8001 75/25 22.5 18.8 0x8002 70/30...

  • Page 42: Section 10 − Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 10 − MAINTENANCE AND TROUBLESHOOTING 10-1. SubArc System Help Codes SubArc Interface SubArc Power Source Sta- Fault Description Digital Help Code tus/Trouble Light HELP will dis- Each flash sequence will play in the up- be followed by a one sec- display, ond pause.
  • Page 43 A complete Parts List is available at www.MillerWelds.com 10-1. SubArc System Help Codes (Continued) SubArc Interface SubArc Power Source Sta- Fault Description Digital Help Code tus/Trouble Light HELP will dis- Each flash sequence will play in the up- be followed by a one sec- display, ond pause.

  • Page 44: Power Source Routine Maintenance

    A complete Parts List is available at www.MillerWelds.com 10-2. Power Source Routine Maintenance Disconnect input power Maintain more often during before maintaining. severe conditions. n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months Δ...

  • Page 45: Accessing Supplementary Protector

    A complete Parts List is available at www.MillerWelds.com 10-4. Accessing Supplementary Protector Turn Off welding power source before checking sup- plementary protector. Supplementary Protector CB1 CB1 protects the 24 VAC portion of the Remote receptacle. Press button to reset breaker. 265690-A 10-5.

  • Page 46: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS Figure 11.1. Circuit Diagram for SubArc AC/DC Digital Series Models OM-265364 Page 40...
  • Page 47 262522-C OM-265364 Page 41...
  • Page 48 Notes Welding Tip: Securely connect work clamp to a clean area close to the weld joint.
  • Page 49 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in.
  • Page 50 Notes...
  • Page 51 Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 52 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 2020 Miller Electric Mfg. LLC 2020−01...

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