Miller SubArc Digital Owner's Manual
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Miller SubArc Digital Owner's Manual

Miller SubArc Digital Owner's Manual

Motor control and remote pendant
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OM-294120A
2023-05
Processes
Submerged Arc (SAW) Welding
Description
Submerged Arc Controller For Automatic
Welding
SubArc Motor Control
And Remote Pendant
Digital CE
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-294120A 2023-05 Processes Submerged Arc (SAW) Welding Description Submerged Arc Controller For Automatic Welding SubArc Motor Control And Remote Pendant Digital CE OWNER’S MANUAL 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

    Power Source Compatibility With 14-Pin To SubArc Digital Converter ....... .

  • Page 4: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC, 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), Commission Regulation(s) and Standard(s).
  • Page 5 DECLARATION OF CONFORMITY For United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 1635 West 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 Regulation(s) and Standard(s).

  • Page 6: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 7: Welding Can Cause Fire Or Explosion

    HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 8: Additional Hazards For Installation, Operation, And Maintenance

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

  • Page 9: California Proposition 65 Warnings

    � To reduce possible interference, keep weld cables as short as ARC WELDING can cause possible, close together, and down low, such as on the floor. interference. � Locate welding operation 100 meters from any sensitive electronic equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

  • Page 10: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION 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 11 � S’assurer que tous les panneaux et couvercles sont correctement LES ACCUMULATIONS DE GAZ en place. risquent de provoquer des blessures � Fixer le câble de retour de façon à obtenir un bon contact métal- ou même la mort. métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

  • Page 12: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    � Brancher le câble de masse sur la pièce le plus près possible de � Les porteurs d’implants médicaux doivent consulter leur médecin la zone de soudage pour éviter le transport du courant sur une lon- et le fabricant du dispositif avant de s’approcher de la zone où se gue distance par des chemins inconnus éventuels en provoquant déroule du soudage à...
  • Page 13 � Affûter l'électrode au tungstène uniquement à la meuleuse dotée LIRE LES INSTRUCTIONS. de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du vi- � Lire et appliquer les instructions sur les étiquettes sage, des mains et du corps.

  • Page 14: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des pro- Pour plus d’informations, consulter www.P65Warnings.ca.gov. duits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malforma- tions ou d’autres troubles de la reproduction. 2-5.

  • Page 15: Section 3 - Definitions

    Do not discard product (where applicable) with general waste. Safe11 Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection � facility. Complete Parts List is available at www.MillerWelds.com 1-1. Additional Safety Symbols And Definitions Contact your local recycling office or your local distributor for further information.

  • Page 16: Miscellaneous Symbols And Definitions

    � Complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions � Some symbols are found only on CE products. Wire Feed Inch Amperage Primary Voltage Down Voltage Primary Current Wire Feed Inch Up A complete Parts List is available at www.MillerWelds.com Degree of Hertz Crater Time...

  • Page 17: Section 4 - Specifications

    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 18: Environmental Specifications

    � Complete Parts List is available at www.MillerWelds.com 4-5. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. B. Information On Electromagnetic Compatibility (EMC) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.
  • Page 19 � Complete Parts List is available at www.MillerWelds.com E. China EEP Hazardous Substance Information 中国电器电子产品中有害物质的名称及含量 China EEP Hazardous Substance Information 部件名称 有害物质 Component Hazardous Substance Name 铅 汞 镉 六价铬 多溴联苯 多溴二苯醚 Do not spra (如果适用) PBDE (if applicable) 黄铜和铜部件 Brass and Cop- per Parts 耦合装置...

  • Page 20: Subarc System Compatibility

    � Complete Parts List is available at www.MillerWelds.com 4-6. SubArc System Compatibility The following power source and accessory models are compatible. The interface will automatically detect the power source and wire drive type connected. � Only like power source models can be connected with parallel or tandem cables. Power Sources: 907620 - SubArc AC/DC 1000 Digital 907621 - SubArc AC/DC 1250 Digital...

  • Page 21: Power Source Compatibility With 14-Pin To Subarc Digital Converter

    Power Source Compatibility With 14-Pin To SubArc Digital Converter The following power sources are compatible with the 14-Pin To SubArc Digital Converter. Will function with current and legacy Miller Big Blues 500, 600, and 800 without 120VAC supplied from the 14-Pin receptacle.

  • Page 22: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Dimensions And Mounting Hole Layout A. SubArc Motor Control Digital Dimensions And Mounting Hole Layout 5/16 in. 8 in. (7.9 mm) (203 mm) Dia. 4 Holes 11-1/2 in. 10-3/4 in.

  • Page 23: Section 6 - System Connections

    SECTION 6 – SYSTEM CONNECTIONS 6-1. Left Side Panel Connections For SubArc Motor Control Digital Turn Off welding power source and weld control disconnect input power before opening ac- cess door. 1 Receptacle 2 Keyway 3 Receptacle RC3 Connection to flux hopper. 4 Receptacle RC1 Connection to welding power source.

  • Page 24: Bottom Panel Connections For Subarc Remote Pendant Digital

    6-2. Bottom Panel Connections For SubArc Remote Pendant Digital Turn Off welding power source and weld control before making connections. 1 Receptacle RC4 Connection To Motor Control Digital 2 Keyway 3 SubArc Remote Pendant Digital (Bottom View) 277882-A 6-3. Remote Receptacle RC1 Information For SubArc Motor Control Digital Function Circuit Contact Information...

  • Page 25: Remote Receptacle Rc4 Information For Subarc Remote Pendant Digital And Motor Control Digital

    6-6. Remote Receptacle RC4 Information For SubArc Remote Pendant Digital And Motor Control Digital Function Circuit Contact Information 42 VDC common. Electrical Input Power 42 VDC. +Accessory RS-485 communication. Accessory Serial Communication −Accessory RS-485 communication. Chassis. Jog up. Start. Push Buttons Stop.

  • Page 26: Terminal Block Tb1 And Tb2 Connections For Subarc Motor Control Digital

    6-7. Terminal Block TB1 And TB2 Connections For SubArc Motor Control Digital Turn Off welding power source and weld control before making connections. Disconnect input power before opening access door. 1 Access Door Remove securing screws and open access door. 2 Terminal Block TB2 3 Terminal Block TB1 4 Securing Screw - Terminal Block...

  • Page 27: Terminal Block Tb1 Connections For Subarc Motor Control Digital

    6-8. Terminal Block TB1 Connections For SubArc Motor Control Digital Terminal Function Information Blank Not used. Blank Not used. Normally open set of contacts* that defaults close when power source contactor energizes after the start button is pressed and preflux has timed out. On digital models, this condition is programmable via auxiliary menus (see Section 7-7).

  • Page 28: 6-10. Subarc Motor Control Digital Plug Connections

    6-10. SubArc Motor Control Digital Plug Connections 278023-B The XXX part no. suffix refers to the cable 9 Flux Hopper Extension Cable Part No. � Motor shown without feed roller guard. length in feet (e.g. 020 suffix is a 20 ft exten- 260623XXX sion cable).

  • Page 29: Section 7 - Operation

    SECTION 7 – OPERATION 7-1. Weld Control Definitions 236564-B Ref. 277880-A OM-294120 Page 24...
  • Page 30 The number of the active program is dis- 21 Setup Push Button LED � When the system interface is turned played here. on, it detects the type of power source The setup push button LED illuminates when and motor that are being connected. 13 Program Push Button the setup display mode is active.

  • Page 31: Weld Sequence Displays

    7-2. Weld Sequence Displays Start: = LED Flashing = LED On CV mode − Start and Crater display wire feed speed in lower display. CV+C mode − Start and Crater display amps in lower display. For all modes − When upper display push button LED is lit, use Adjust control to change corresponding display value.

  • Page 32: Weld Sequence Parameters In A Program

    7-3. Weld Sequence Parameters In A Program � For more information on Sequence push buttons, see Section 7-2. If time is set to zero in Weld Sequence, weld- ing continues until stop button is pressed. If time is set to zero in any timed sequence except Weld, the sequence is skipped.

  • Page 33: Setup Screens

    7-4. Setup Screens = LED Flashing = LED On � Press the setup push button to enter the setup screens. If the pa- rameter is program specific, the active program is displayed in the program display. The active program can be changed by pressing the Program push button and then selecting the desired program with the Adjust control.

  • Page 34: Setup Screens (Continued)

    7-5. Setup Screens (Continued) = LED Flashing = LED On � Press the setup push button to enter the setup screens. If the parameter is program specific, the active program is displayed in the program display. The active program can be changed by pressing the Program push button and then selecting the de- sired program with the Adjust control.

  • Page 35: Setup Screens (Continued)

    7-6. Setup Screens (Continued) = LED Flashing = LED On RUNI � Press the setup push button to enter the setup screens. If the pa- rameter is program specific, the active program is displayed in the program display. The active program can be changed by pressing AUTO the Program push button and then selecting the desired program with the Adjust control.

  • Page 36: Auxiliary Menus Screens

    7-7. Auxiliary Menus Screens An auxiliary menu is provided when both the Sequence and Setup buttons are pressed simultaneously. The Setup and Sequence button LEDs flash when in the auxiliary menu. Press the Setup button to scroll forward or press the Sequence button to scroll backwards through the auxili- ary menu.

  • Page 37: Auxiliary Menus Screens (Continued)

    7-8. Auxiliary Menus Screens (Continued) = LED Flashing = LED On � Lock Hold Lock Hold is indicated by HOLD in the upper display. Lock Hold is set to off by default and OFF is shown in the lower display. If Lock Hold is de- sired, press the lower display push button to illuminate the lower display push button LED then rotate the adjust control to change the setting to The Lock Hold feature only works when locks are active and provides...

  • Page 38: Auxiliary Menus Screens (Continued)

    7-9. Auxiliary Menus Screens (Continued) = LED Flashing = LED On � Number of Programs The number of programs is indicated by NUMB in the upper display and PROG in the lower display. The number of user allowed programs (1 through 15) is shown in the program display.

  • Page 39: Auxiliary Menus Screens (Continued)

    7-10. Auxiliary Menus Screens (Continued) = LED Flashing BUTN = LED On � Motion Control Motion control is indicated by SB1 or SB2 in the lower display and is used to set when the side beam relay engages. When “BUTN” is shown in the upper display, the side beam relay will engage when the start but- ton is pressed and preflux has timed out.

  • Page 40: Auxiliary Menus Screens (Continued)

    � Power Source Selection (14-Pin To SubArc Digital Converter Only) � (see 14-Pin To SubArc Digital Converter owner’s manual). When PS is shown in the program selection window, you can cycle 1440 through the list of compatible power sources by rotating the turn knob.

  • Page 41: Auxiliary Menus Screens (Continued)

    7-12. Auxiliary Menus Screens (Continued) = LED Flashing = LED On PREV � Software Revision Level When P. REV is shown in the upper display, the process control board revision level is shown in the lower display. When C.REV is shown in the upper display, the conversion box control board revision level is shown in the lower display.

  • Page 42: 7-13. Remote Program Select For Subarc Motor Control Digital

    7-13. Remote Program Select For SubArc Motor Control Digital � There are two methods to remotely change programs. Method 1 Remote Program Select 1 In the auxiliary menu, turn Remote Program Select Off (see Section 7-10, Remote Program Select). Connecting Terminal Block TB1 Remote Program Select 1 (see Section 6-8) to Terminal Block TB2 Common (see Section 6-9) will increment the program.

  • Page 43: Section 8 - Maintenance And Troubleshooting

    pliers needlenose � knife steelbrush nutdriver Complete Parts List is available at www.MillerWelds.com chippinghammer SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance solderiron heavy-duty workclamp light-duty workclamp wirecutter frontcutter stripcrimp Disconnect power before maintaining. � Maintain more often during severe conditions. �...

  • Page 44: Troubleshooting Table

    � Complete Parts List is available at www.MillerWelds.com 8-2. Troubleshooting Table Trouble Remedy Unit is completely inoperative. Check 24 VAC input power and be sure it is energized. Wire does not feed during jogging. Place Power Switch S1 in On position. Check 24 volts AC input power and be sure it is energized.

  • Page 45: Help Codes

    � Complete Parts List is available at www.MillerWelds.com 8-3. Help Codes A. SubArc System � HELP will display in the upper display, and the code number will display in the lower display. � Each flash sequence will be followed by a one second pause. The sequence will then repeat. SubArc Power SubArc Source...
  • Page 46 � Complete Parts List is available at www.MillerWelds.com Indicates a save was attempted to a locked card. This refers to the physical switch on the memory card. Unlock the memory card and try 6 Quick, 4 Slow Memory Card Locked again.

  • Page 47: Section 9 - Electrical Diagrams

    SECTION 9 – ELECTRICAL DIAGRAMS 277430-A Figure 9-1. Circuit Diagram For SubArc Motor Control Digital OM-294120 Page 42...
  • Page 48 277431-A Figure 9-2. Circuit Diagram For SubArc Remote Pendant Digital OM-294120 Page 43...
  • Page 49 Notes...
  • Page 50 Notes...
  • Page 51 Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � CoolBelt, PAPR Blower, and PAPR Face...

  • Page 52: Owner's Record

    Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-05...

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