Miller Electric Subarc DC 1000 Owner'S Manual Download Page 1

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Processes

Description

Multiprocess Welding

Arc Welding Power Source

OM-229 253F

2010

−

Subarc DC 1000/1250

Visit our website at

www.MillerWelds.com

File: Multiprocess

CE And Non-CE

Summary of Contents for Subarc DC 1000

Page 1: ...Processes Description Multiprocess Welding Arc Welding Power Source OM 229 253F 2010 11 Subarc DC 1000 1250 Visit our website at www MillerWelds com File Multiprocess CE And Non CE...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...Safety Symbols 12 3 5 Symbol Definitions 13 3 6 WEEE Label For Products Sold Within The EU 13 SECTION 4 INSTALLATION 14 4 1 Important Information Regarding CE Products Sold Within The EU 14 4 2 Seria...

Page 4: ...04 108 EC Electromagnetic Compatibility Standards IEC 60974 1 2005 Arc Welding Equipment Welding Power Sources IEC 60974 10 2007 Arc Welding Equipment Electromagnetic Compatibility Requirements EN 504...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eq...

Page 6: ...less they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to t...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Page 8: ...web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website ww...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 10: ...u laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer...

Page 11: ...lt rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz com...

Page 12: ...stan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences D L nergie lectromagn tique risque de provoquer d...

Page 13: ...r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Ap...

Page 14: ...OM 229 253 Page 10...

Page 15: ...ur head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away f...

Page 16: ...ide label double check all connections jumper link positions and input voltage before applying power S 179 290 1 4 5 3 2 V A V 3 1 96 1 2 3 4 5 6 8 7 9 3 3 Electric Shock And Airflow Label S 179 563 1...

Page 17: ...urrent Protective Earth Ground I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current 3 Phase Power Source With AC DC Output Temperature Ventilating And Air Circulating Fan Increase...

Page 18: ...is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compati...

Page 19: ...AMPERES VOLTS 4 5 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling...

Page 20: ...side of unit 3 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Secti...

Page 21: ...s A 30 in 762 mm Including lift eye B 23 in 584 mm C 38 in 966 mm Including strain relief D 35 in 889 mm E 1 1 4 in 32 mm F 21 1 8 in 537 mm G 1 1 8 in 29 mm H 7 16 in 11 mm Dia Weight 1000 Amp Models...

Page 22: ...rtion of RC8 1T and RC9 from overload CB2 protects 24 volts AC portion of RC8 and 1T from overload Press button to reset protector 4 Positive High Inductance Submerged Arc Weld Output Terminal Use thi...

Page 23: ...volt age sense wire is 12 gauge or larger For better performance for most Sub Arc SAW applica tions make connections to the Submerged Arc weld output terminal Polarity For DCEP Reverse Polarity conne...

Page 24: ...emote 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 vol...

Page 25: ...nse leads detect arc voltage ac curately Best starts arcs and most reliable results BAD Sense lead is affected by weld current Due to voltage drops across work piece arc voltage may be low causing nee...

Page 26: ...g need for deviation from standard procedures BAD Current flow from lead affects trail sense Current flow from trail affects lead sense Neither sense lead picks up the correct work voltage causing sta...

Page 27: ...0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120...

Page 28: ...ck 0 to 10 volts DC 1 volt per 100 amperes H Voltage feedback 0 to 10 volts DC 1 volt per 10 arc volts 115 VOLTS AC I I 115 volts 15 amperes 60 Hz DC Protected by circuit breaker CB1 J J Contact closu...

Page 29: ...nal strip 1T Turn Off power before open ing terminal strip cover 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain Relief Customer Supplied Secure cord in strain relief Reinstall and secure access pa...

Page 30: ...f a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements B 1000 Ampere Rated Welding Output Failure to follow these electri...

Page 31: ...nuts 1 Disconnect and lockout tag out input power before installing or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label only one is on unit 2 Jumper Link Move...

Page 32: ...nd Current Sensor Optional Connect green or green yellow grounding conductor to welding power source ground ing terminal first If unit is equipped with op tional ground current sensor route ground ing...

Page 33: ...ill read 0 zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant Voltage position voltmeter dis plays p...

Page 34: ...eld Cables Weld Terminals Every 6 Months OR Inside Unit monthly dur ing heavy service 6 2 Fuse F1 Ref 802 295 Turn Off power before open ing rear access door 1 Fuse F1 See Parts List For Rating Fuse F...

Page 35: ...sition see Section 4 16 Clean and tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD...

Page 36: ...OM 229 253 Page 32 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 37: ...OM 229 253 Page 33 236 683 A...

Page 38: ...ge 34 SECTION 8 PARTS LIST 802 296 D Figure 8 1 Main Assembly Hardware is common and not available unless listed 33 25 32 31 27 28 1 3 4 5 6 2 4 5 26 13 14 15 3 25 22 24 23 1 19 12 8 37 17 11 18 16 10...

Page 39: ...24 W 193 473 CONTACTOR size 3 1 2 3P 24VAC 1 25 217 136 LABEL warning electric shock 2 25 176 254 LABEL general precautionary wordless intl CE models only 2 26 193 462 BRACKET contactor mount 1 27 163...

Page 40: ...48 439 CONNECTOR SOCKETS 1 PLG5 152 249 CONNECTOR SOCKETS 1 PLG16 158 719 CONNECTOR SOCKETS 1 3 CR3 052 964 RELAY encl 24VDC DPDT 1 4 CR5 006 393 RELAY encl 24VAC DPDT 1 5 CB1 2 093 995 SUPPLEMENTARY...

Page 41: ...m 2 26 PC2 232 116 CIRCUIT CARD ASSY display w program 60 and 50 Hz Models 1 PLG10 153 501 CONNECTOR SOCKETS 1 PLG11 148 439 CONNECTOR SOCKETS 1 27 CR2 116 592 RELAY encl 24VDC 3PDT 1 28 192 174 STAND...

Page 42: ...ockey puck 6 6 191 247 HEAT SINK rectifier snowflake3 000 3 7 191 246 CLAMP thyristor rectifier 8 187 3 PLG1 158 720 CONNECTOR SOCKETS 1 TP3 192 731 THERMOSTAT rectifier 1 TP6 168 894 THERMOSTAT recti...

Page 43: ...put connection CE models only 1 7 R3 097 459 RESISTOR WW fxd 375W 20 ohm for units w o low ocv 1 8 FM 032 605 MOTOR 1 4HP 230VAC 1625RPM 50 60Hz 1 9 183 167 CONNECTOR clamp cable 2 000 1 802 298 C Har...

Page 44: ...Notes...

Page 45: ...Notes...

Page 46: ...Notes...

Page 47: ...bles No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Cont...

Page 48: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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