Miller Subarc AC/DC 1000 Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Subarc AC/DC 1000
  6. Owner's manual

Miller Subarc AC/DC 1000 Owner's Manual

Welding machine miller subarc ac/dc 1000; subarc ac/dc 1250
Hide thumbs
Table of Contents

Advertisement

Quick Links

OM-246 011D
2012−10
Processes
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source
Subarc AC/DC 1000/1250
CE
File: Submerged (SAW)
Visit our website at
www.MillerWelds.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Subarc AC/DC 1000 and is the answer not in the manual?

Questions and answers

Related Manuals for Miller Subarc AC/DC 1000

Summary of Contents for Miller Subarc AC/DC 1000

  • Page 1 OM-246 011D 2012−10 Processes Processes Submerged (SAW) Welding Description Arc Welding Power Source Subarc AC/DC 1000/1250 File: Submerged (SAW) Visit our website at 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: 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 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 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. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 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 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. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, 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- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-246 011 Page 10...

  • Page 15: Section 3 − Definitions

    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. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

  • Page 16: Miscellaneous Symbol Definitions

    3-2. Miscellaneous 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 Circuit Breaker Rated No-Load Rated Supply (Supplementary...

  • Page 17: 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 18: Duty Cycle And Overheating

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

  • Page 19: Selecting A Location

    4-6. Selecting a Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks Movement beyond opposite side of unit. Line Disconnect Device Locate unit near correct input power supply. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 20: Weld Output Terminals And Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 OM-246 011 Page 16...

  • Page 21: Connecting Weld Output Cables

    4-8. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 803 778-B cable terminal and copper bar. Make Weld Cable Terminal Turn off power before connecting to sure that the surfaces of the weld cable weld output terminals. Copper Bar terminal and copper bar are clean.

  • Page 22: Terminal Strip Te1, Te2 And Remote 14 Receptacle Rc7 Information

    4-9. Terminal Strip TE1, TE2 and Remote 14 Receptacle RC7 Information Socket Terminal Terminal Information on RC7 on TE2 on TE1 − − 24 volts, 12 amperes, AC. Protected by circuit breaker CB2. 24 VOLTS AC − − Contact closure to A completes 24 volts AC contactor control circuit.

  • 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. 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 25 C. 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 26: 115 Volts Ac Receptacle And Circuit Breaker 460 Volt Models

    4-11. 115 Volts AC Receptacle And Circuit Breaker 460 Volt Models 115 V 15 A AC Receptacle Power is shared between the du- plex receptacle and the 115 volt output connections and the Remote 14 receptacle (see Section 4-9). 115 VAC Supplementary Protector CB1 CB1 protects 115 volts AC recep- tacle and Remote 14 receptacle...

  • Page 27: Electrical Service Guide

    4-13. Electrical Service Guide A. 1000 Models 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 28: Connecting Input Power

    4-14. 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. input1 2012−05 / Ref. 247479-B / 803 766-C OM-246 011 Page 24...
  • Page 29 4-14. Connecting 3-Phase Input Power (Continued) Input Power Conductors (Customer Connect input conductors L1 (U), L2 (V) and Installation must meet all National Supplied Cord) L3 (W) to welding power source line and Local Codes − have only qualified terminals. persons make this installation.

  • Page 30: Matching Primary Lines L1, L2, And L3 When Using Multiple Ac Units

    4-15. 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- Meter Polarity Does Not Matter ing the test point (TP) terminal strip TE2.

  • Page 31: Section 5 − Making Weld Output Connections

    SECTION 5 − MAKING WELD OUTPUT CONNECTIONS 5-1. Work And Electrode Cable Connections For Single DC or AC Arcs Turn welding power source before opening access door. NOTICE − If there are any questions regarding this procedure, contact the factory before connecting units. Connect the proper size and number of weld output cables (see Section 4-7) to one or more of the welding...

  • Page 32: Connecting Multiple Units

    NOTICE − All units being paralleled must be in CC position (see Section To Next AC Unit When running multiple units in parallel, Parallel Controller (Miller part number 194711) Second Unit (And First Unit must also be used. Install con- Following Units)

  • Page 33: Using Ac Arcs Terminal Strip Te1 Connections

    5-3. Using AC Arcs Terminal Strip TE1 Connections Turn welding power source before opening access door. DC output units do not require synchronization with AC output units. Tools Needed: NOTICE − All units must be set to the same balance (see Section 6) when multiple units are connected in AC.

  • Page 34: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Controls For Non-CE Models Output Control Switch control setting 40/60-18 Hz, 33/67-60 Hz, 30/70-18 Hz, or 20/80- 18 Hz. A/V (Amperage/Voltage) Adjustment For weld output, place switch in On position. Control For remote control of output, make connec- Power Switch w/Indicator Light tions to Remote 14 receptacle (see Section Use control to select weld voltage when CC/...

  • Page 35: Front Panel Controls For Ce Models

    6-2. Front Panel Controls For CE Models Output Control Switch control setting 40/60-15 Hz, 33/67-50 Hz, 30/70-15 Hz, or 20/80- 15 Hz. For weld output, place switch in On position. A/V (Amperage/Voltage) Adjustment Control For remote control of output, make connec- Power Switch w/Indicator Light tions to Remote 14 receptacle (see Section Use control to select weld voltage when CC/...

  • Page 36: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect input power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ...

  • Page 37: Access Area Supplementary Protectors

    7-3. Access Area Supplementary Protectors Turn Off welding power source before checking cir- cuit breakers. Supplementary Protector CB2 CB2 protects the 24 VAC portion of the Remote 14 receptacle. Press button to reset breaker. 247 476-C 7-4. Troubleshooting Trouble Remedy No weld output;...

  • Page 38: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8.1. Circuit Diagram For Sub Arc AC/DC 1000 (460 V Input) Model OM-246 011 Page 34...
  • Page 39 244 959-C OM-246 011 Page 35...
  • Page 40 Figure 8.2. Circuit Diagram For Sub Arc AC/DC 1250 (400 V Input) Model OM-246 011 Page 36...
  • Page 41 247 290-D OM-246 011 Page 37...

  • Page 42: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 1000 Model Illustrated 247 435-D Figure 9-1. Main Assembly OM-246 011 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ... 246960 Panel, Side ............
  • Page 44 Hardware is common and not available unless listed. 1000 Model Illustrated 247 433-D Figure 9-2. Front Panel Assembly OM-246 011 Page 40...
  • Page 45 ....246170 Nameplate, SUBARC AC/DC 1000/1250 Lower .....
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Front Panel Assembly (Figure 9-1 Item 16) (continued) ... . 247090 LED Assy, Yellow W/Terminals ........
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-3. Rear Panel Assembly (Figure 9-1 Item 9) ... . . 032605 Motor, Cap Perm SP 1/4HP 230VAC 1625RPM ..... .
  • Page 48 Notes...
  • Page 49 Notes...
  • Page 50 Notes...
  • Page 51 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...

  • Page 52: Options And Accessories

    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 2012 Miller Electric Mfg. Co. 2012−01...

This manual is also suitable for:

Subarc ac/dc 1250

Table of Contents