Submerged Arc Components

Heavy Industrial Applications Processes

Submerged Arc (SAW) Electroslag (ESW)

Issued Mar. 2008 Index No. AY/12.0

Submerged Arc Welding

Quick Specs

Railcar Shipbuilding Heavy Fabrication Pipe Industry Pressure Vessel

The Power of Blue .

HDC 1500 DX Controller

Sub Arc DC 650

The powerful Sub Arc DC power sources provide outstanding versatility, plus the endurance and high amperage output to handle the biggest heavy industrial applications.

Adaptable AC/DC, CV controller for use in Sub Arc applications.

Look no further than Miller to find your industrys Sub Arc welding solutions featuring the flexible HDC 1500 controllers and Sub Arc DC series! We offer complete systems that can make you more productive and help lower your weld costs with less power consumption, increased deposition rates, and faster travel speeds!

3 years parts and labor; original main power rectifier parts are warranted for 5 years. Reliability built into each controller.

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters
Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125

Web Site
www.MillerWelds.com

HDC 1500 A and 1500 DX Controllers

Internal terminal strip is able to integrate with positioners, sidebeams, turning rolls and other peripheral equipment.

HDC 1500 A (Analog Controller)

HDC 1500 DX (Digital Controller)

Specifications
Controller HDC 1500 A

(Subject to change without notice.)

Welding Power Source Type Constant Current (CC), Constant Voltage (CV), AC or DC, with Remote Contactor and Output Control Capabilities Constant Voltage (CV), AC or DC, with Remote Contactor and Output Control Capabilities Weld Voltage and Amperage Capacity (AC or DC) 0 60 V 0 1500 A 0 100 V 0 1500 A Dimensions H: 7 in (178 mm) W: 11-1/4 in (286 mm) D: 11-1/2 in (292 mm) Weight 18 lb (8.2 kg)

Type of Input from Welding Power Source Single-phase 115 VAC, 3.5 Amps, 50/60 Hz Single-phase 115 VAC, 3.5 Amps, 50/60 Hz

HDC 1500 DX

(Without CE) certified to both the Canadian and U.S. Standards for welding equipment. 50/60 Hz models with CE Specifications are manufactured according to the Standard IEC-60974-5.

HDC 1500 A and 1500 DX Control Panels

1 2 3
11 10
10 0 20 30 40 50 60 300 0 600 900 1200 1500

1
15
Program Volts Time (sec)

VOLTS

AMPERES

2
Wire Speed Start Crater Amps

5 6 7 8 9 10

4 5 6 7 8 9

12

16

3 4

Pre-Postflow

Sequence

Adjust

Setup

17
13

18 19

11 12 13
Do not touch live electrical parts. Disconnect input power before maintaining or servicing. Keep all covers, guards, and panels securely in place.

14

14

MADE

15
MADE

HDC 1500 A (Analog Controller) 1. Jog Speed 2. Preflux Time 0 10 Seconds 3. Run-In Speed 4. Crater/Burnback Output 5. Crater Speed 6. Crater Time 05 Seconds 7. Burnback Time 05 Seconds 8. CC/CV Switch 9. Postflow Time 010 Seconds 10. Voltage Meter 11. Power Switch 12. Output Control Knob 13. Start Button 14. Stop Button 15. Amperage Meter 16.Wire Feed Speed Control Knob 17. Indicator Light 18. Wire Inch Up 19. Wire Inch Down

HDC 1500 DX (Digital Controller) 1. Program Display 2. Program Push Button 3. Adjust Control 4. Sequence Push Button 5. Upper Display 6. Upper Display Push Button 7. Lower Display 8. Lower Display Push Button 9. Flux Push Button 10. Setup Push Button 11. Start Button 12. Power Switch 13. Stop Button 14. Wire Inch Up 15. Wire Inch Down

Miller Tractor
The Miller Tractor is a highly flexible self-contained welding unit comprised of a travel system and a variety of quality engineered components designed to produce precision, high-quality Submerged Arc welds. Tractor comes complete with a main mounting mast and handle assembly, mounting arm for one wire reel, vertical and horizontal 4 x 4 in slides, control support arm and one set of two adjustable guide roll arms. The friction drive heavy-duty travel carriage utilizes a positive chain drive powering four rubber-tired wheels with a closed-loop tach feedback for accurate speed control. A manual clutch enables freewheeling movement of the carriage. Remote pendant control box houses forward/stop/reverse switch and infinitely variable 4-turn speed potentiometer as well as LED display in IPM or cm/min. Available with either the HDC 1500 DX or 1500 A (see page 2). Package Includes: Tractor HDC weld controller RAD-400 drive motor

25 lb (11.3 kg) capacity flux hopper with valve Wire reel Torch

Tractor guide rolls Remote start/stop control Wire straightener

Specifications
Wire Feed Speed Wire Size Range

(Subject to change without notice.)

Max. Incline Gun Positioning Supply Voltage Drive Slides (from HDC 1500) Motor 4 in (101.6 mm) vertical and horizontal stroke 115 VAC, 1-Phase, 50/60 Hz, 200 watts Max. Spool Size Capacity Travel Speed Dimensions* Weight

20 400 IPM 3/32 5/32 in 30 depending (2.4 4.0 mm) on mounting (51 1016 cm/min) configuration

24 VDC 60 lb (27 kg) permanent magnet gear motor

466 IPM H: 43-3/8 in (1102 mm) 162 lb (10 168 D: 35-1/2 in (903 mm) (73 kg) cm/min) without flux/wire

* Note: Width will vary depending on how system is configured.

Tractor Speed Control Panel and Line Drawings

6 1 2 3
IPM CM MIN

7 8 9

10 4 5 11 12 13

1. 2. 3. 4. 5.

Forward Motion Commanded Indicator Reverse Motion Commanded Indicator Hold (Stop) Mode Active Indicator Auto Enable Mode Manual Carriage Mode

6. Speed and Parameter Display 7. Speed Display Indicator (Calibrated in Inches per Minute) 8. Speed Display Indicator (Calibrated in Centimeters per Minute)

9. 10. 11. 12. 13.

Programming Mode Indicator (Flashing) Speed Adjustment Command Forward Motion Neutral Command Reverse Motion

Summit Arc 1000/1250 Power Sources

Variable balance AC provides excellent arc starting and positive arc re-ignition throughout the weld cycle for superior arc performance and quality. Phase-shifting capability and optional variable balance plugs refine arc for specific needs. Fan-On-Demand cooling system only works when needed reducing energy usage and noise

Specifications
AC or DC Rated Output (Based on a 10 minute duty cycle) 1000 A at 44 V, 100% Duty Cycle

(Subject to change without notice.)

Max. OpenCircuit Voltage RMS Amps Input at Rated Load Output, 3-Phase at NEMA Load Voltages and Class I Rating 400V (50/60 Hz) 460V (60 Hz) 575V (60 Hz) KVA KW 140 3* 124 3* 100 3* 98 53 2.37* 0.95*

Amperage/Voltage Range

Dimensions H: 44 in (1118 mm) W: 27-1/4 in (692 mm) D: 46 in (1168 mm)

Weight 1225 lb (540 kg)

250 1250 A in CC mode 71 V 2544 V in CV mode

*While idling.
Certified to both the Canadian and U.S. Standards for welding equipment. 50/60 Hz models with CE Specifications are manufactured according to the Standard IEC-60974-1.

Control Panel
1. Output Control Switch 2. A/V (Amperage/Voltage) Control Switch 3. Power On Indicator Light 4. Power Pushbutton Switch 5. A/V (Amperage/Voltage) Adjustable Control 6. High Temperature Shutdown Indicator Light 7. Receptacle (115 VAC, 12 A on 460 and 575 V models; 230 VAC, 16 A on 400 V models)

1 2 3 4

5 6 7

Note: CC/CV Switch is mounted inside access area.

Performance Data
Volt/Amp Curve DC/CV
80 70 60 50 40 30 20 10 0 200 400 600 800 1000 1200 1400 1600 80 70 60 50 40 30 20 10 0 200 400 600 800 1000 1200 1400 1600

Volt/Amp Curve DC/CC 60Hz

80 70 60 50 40 30 20 10 0 200

Volt/Amp Curve AC/CV

80 70 60 50 40 30 20 10 400 600 800 1000 1200 1400 1600 0 200

Volt/Amp Curve AC/CC

400

600

800 1000 1200 1400 1600

Sub Arc DC 650/800 and Sub Arc DC 1000/1250 Power Sources

DC multiprocess capability, versatility and outstanding performance in SAW process. Line voltage compensation keeps welding parameters constant even when input voltages change 10%. Eliminates need to change welding parameters throughout the day. Fan-On-Demand cooling system only works when needed reducing energy usage and noise. Fully populated terminal strip for sense leads and remote on/off. 15 amp 115 VAC duplex receptacle allows operators the flexibility to run grinders, drills, coolers, etc. from the power source without the need for additional 115 VAC power in the weld area. Power efficient for exceptional value and return on your investment. Digital meters for presetting and monitoring welding voltage or amperage. Remote control capability allows operators fine tuning capability at an extended distance, with the HDC 1500 Controllers. See Literature Index No. DC/19.8 for additional information.

Specifications
Model Rated Output Sub Arc DC 650 A at 44 VDC, 650/800 100% Duty Cycle

(Subject to change without notice.)

Amperage/ Voltage Range 50 815 A 10 65 V 100 1250 A 10 60 V 66 VDC Max. OpenCircuit Voltage* 72 VDC Amps Input at Rated Output, 3-Phase, 50/60 Hz 230 V 380 V 400 V 440 V 460 V 520 V 575 V 126 3.8** 180 5.8** 77 73 1.9** 1.8** 109 104 5.2** 5.0** 66 63 54 50.4 1.6** 1.9** 1.1** 1.4** 94 4.5** 90 2.9** 72 2.4**

Mode CC CV

KVA

KW

Dimensions

Weight 545 lb (247 kg) 644 lb (292 kg)

Sub Arc DC 1000 A at 44 VDC, CC 1000/1250 100% Duty Cycle CV

50 34.8 H: 27-1/4 in (692 mm) 1.52** 0.76** including lift eye W: 22-1/4 in (565 mm) D: 36 in (914 mm) 73 53 3.2** 0.5** including strain relief

*Open-circuit voltages in CV mode are factory set at values less than indicated for CC.
Certified to both the Canadian and U.S. Standards for welding equipment.

**While idling.

50/60 Hz models with CE Specifications are manufactured according to the Standard IEC-60974-1.

Control Panels
4

1. Arc Force (DIG) Control 2. Remote Amperage/Voltage Control Switch 3. Output Switch (Contactor) 4. Process Switch 5. Digital Meters 6. Amperage/Voltage Adjustment Control 7. High Temperature Shutdown Indicator Light 8. Power Switch with Indicator Light

SMAW DIG
SUB ARC

V VOLTS
400 350 CC CV 300 600 250 650 200 700 450 500 550

A AMPS

1
0 100

ARC FORCE

PROCESS

2 3

A/V
ON PANEL

150 100 750

5 6
HIGH TEMP SHUTDOWN

MIN
REMOTE REMOTE

V A

800 MAX

7
ON

OUTPUT

CONTROL

A/V ADJUST

POWER OFF

Sub Arc DC 650

CC/CVDC Welding Power Source

MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI 228225 A

4
SMAW DIG
SUB ARC

V VOLTS
600 500 CC 400 CV 700 800 900

A AMPS

1
0 100

1000 300 1100 200 100 MIN

ARC FORCE

PROCESS

2
ON

A/V
PANEL

3
REMOTE REMOTE

V A

1200 MAX

HIGH TEMP SHUTDOWN

5 6 7
ON

8
A/V ADJUST
POWER OFF
MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI 229210 A

OUTPUT

CONTROL

Sub Arc DC 1000

CC/CVDC Welding Power Source

Components and Accessories

RAD Wire Drive Assemblies
Miller offers either standard- or high-speed 115-volt heavy-duty wire drive assemblies. The RAD-400 has a wire feed speed range of 20 400 inches per minute (0.5 10 MPM). The RAD-780 has a wire feed speed range of 30 780 inches per minute (0.7 19.8 MPM). Included adapter plate allows mounting to 2-1/2, 4-1/4, and 4-5/8 inch bolt-hole patterns. RAD-400 #195 265 Standard-speed, right-angle wire drive assembly. RAD-780 #195 266 High-speed, right-angle wire drive assembly.
Included adapter plate allows mounting to 2-1/2, 4-1/4, and 4-5/8 inch bolt hole patterns.

Submerged Arc Torches

Accessories
Wire Straightener #199 733 For RAD-400 (standard-speed) or RAD-780 (high-speed) wire drive assembly. For wires 1/16 7/32 in (1.6 5.6 mm).

OBT 600 #043 923 600 amp, 100 percent duty cycle torch with concentric flux flow nozzle. Can be used with 1/16 7/32 in (1.6 5.5 mm) wire. OBT 600 Torch Body Extensions 1 inch #043 967 2 inch #043 969 4 inch #043 973 6 inch #043 975

Light-Duty Cross Slide #195 411 Allows 6 inches of travel adjustment. Two units can be stacked to provide vertical and horizontal movement. Not recommended for tandem. Heavy-Duty Cross Slide #194 783 One-inch diameter, precision, hardened and ground guide rods provide a perfect path for the sealed linear bushings, and smooth accurate movement of the weld head. Allows for 6 inches of travel adjustment and has a load capacity of 200 lb. Recommended for tandem.

Drive Rolls
V Knurled drive rolls for use with hard-shelled cored wires. 1/16 in (1.5 mm) #132 955 5/64 in (2.0 mm) #132 960 3/32 in (2.4 mm) #132 961 7/64 in (2.8 mm) #132 962 1/8 in (3.2 mm) #132 963 5/32 in (3.9 mm) #193 700 3/16 in (4.7 mm) #193 701 7/32 in (5.5 mm) #193 702

OBT 1200 #043 900 1200 amp, 100 percent duty cycle torch with concentric flux flow nozzle. Can be used with 1/16 7/32 in (1.6 5.5 mm) wire. OBT 1200 features a replaceable breakaway adapter end to prevent costly damage should torch run into an obstruction. OBT 1200 Torch Body Extension #043 981 Overall length with extension is 9 in. Actual length of extension is 8-1/2 in.

Wire Reel #108 008 For 60 lb (27 kg) coil of wire. Requires Spool Support Assembly (#119 438). Spool Support Assembly #119 438 For 60 lb (27 kg) wire reel. Cable Kit for HDC 1500 Controllers #195 308 Includes 30 ft (9 m) 14-pin interconnect cable and 10 ft (3 m) motor cable. Motor Extension Cable #195 342 25 ft (7.6 m) extension for the motor cable. Extension Cables 25 ft (7.6 m) #043 725 50 ft (15 m) #043 726 75 ft (23 m) #043 727 14-pin welding power source control cable. Extends distance between power source and controller.

Torch Contact Tips

Wire Size 1/16 in (1.6 mm) 5/64 in (2.0 mm) 3/32 in (2.4 mm) 7/64 in (2.8 mm) 1/8 in (3.2 mm) 5/32 in (4.0 mm) 3/16 in (4.8 mm) 7/32 in (5.6 mm) OBT 600 #192 700 #192 701 #192 702 #192 703 #192 704 #192 705 #192 706 #192 707 OBT 1200 #192 141 #199 026 #192 142 #200 771 #192 143 #192 144 #192 136 #200 756

Flux Handling Equipment

Flux Hopper with Valve #194 775 Flux hopper with automatic flux valve will carry 25 lb of flux. The opening is sized to allow hook-up of any flux-hopper-mounted recovery system. A slag screen is also provided.

Flux Recovery Systems Weld Engineering 1-508-839-9875 American Vacuum 1-800-321-2849 Invincible 1-800-282-6999

Questions and Answers

Q. Why should I sell/buy Miller Electric Submerged Arc welding equipment? Miller has taken what they have done for the GMAW and GTAW processes and developed a power source, controllers and wire drive assembly combination that is specific to the SAW (Submerged Arc welding) process. In the past, standard multi-process equipment was used to accommodate this process. Through our research and development it was discovered that these power sources, although able to weld the SAW process, were not optimized to run as good as our competition. Much work has been done with arc development to assure our customers will be getting the performance they demand with the SAW process. There is now an alternative to the old standbys when it comes to the SAW process. Q. Does Miller have a full offering for the Submerged Arc process? Miller offers weld controllers, wire drive assembly, power sources, flux hoppers and torches all developed together to offer you the best performance from a system approach. When used in conjunction with each other Miller can assure you that these items have been tested together to optimize their performance. Q. Can Miller Submerged Arc equipment be used with equipment other then Miller? No: Because of the optimized performance that a Miller system offers we do not recommend mixing other manufacturers power sources, controllers or wire drive assemblies. Q. Why do I need to use sense leads? Sense leads are critical to obtaining correct arc voltage to optimize the system. When sense leads are not used the system supplies the pre-set voltage at the studs of the power source, not at the arc. Voltage drop in the work piece and cables is not accounted for and therefore a lower voltage than what is preset will be delivered to the arc and can cause poor arc performance. Q. Does it really matter where I hook the sense leads up? Yes: The proper placement of sense leads is as important as using them. The proper placement is covered in the owners manuals of the power sources and controllers. Q. Why is the sense lead connection only on the power source now? This allows the communication between the power source and control to be faster and more accurate. This also promotes good starts. Q. What power sources are recommended to go along with the Miller controls? DC Power Sources Sub Arc DC 650 Sub Arc DC 800 Sub Arc DC 1000 Sub Arc DC 1250 AC/DC Power Sources Summit Arc 1000 Summit Arc 1250 Part Number #907 338 #907 344 #907 342 #907 343 with CE #903 530 #903 570 (50/60 Hz, 400 V)

Q. Why are the Deltaweld and Invision no longer recommended? They do not have the capability to hook up sense leads externally for accurate arc voltage. The power sources mentioned above have a terminal strip to accommodate this sense lead hookup. Q. When should the Summit Arc 1000/1250 be recommended? The Summit Arc 1000/1250 can be used for a trail arc in a standard tandem setup. The Summit Arc is also an AC/DC, CC/CV power source with many advantages over a standard DC power source. Please call Miller Electric at 920-734-9821 and ask for a Submerged Arc specialist to help you with your decision. Q. What is a RAD-400 and RAD-780? The RAD stands for right angle drive and it is Millers wire drive assembly for wire diameters from 1/16 1/4 in. The 400 and 780 represent the highest wire feed speed of each motor. The RAD-400 is recommended for most sub arc applications using wires larger than 5/64 in (2 mm). Q. Does Miller Electric have fluxes and wire for Submerged Arc welding? No they do not. Q. What fluxes will work with the Miller Submerged Arc equipment then? If a flux and wire combination is being used with current equipment, that same combination can be used with the Miller Electric equipment. If you are looking for a new flux and wire, or increased deposition is a consideration, then the Hobart/Tri-Mark consumables should be considered. Please contact them through your local distributor or call Hobart at 937-332-5135 and ask for their recommendations. Q. Can I use the Miller flux hopper with preheated flux? Yes. We have improved the design of the flux hopper to be able to accommodate hot flux whether preheated or reclaiming directly after the weld. The hopper also comes standard with an electric valve that can be controlled manually or from the controller.

Typical Installation
*Sense leads connected to the power source are required for optimal performance. AC or DC Welding Power Source Cable Kit #195 308 (Includes #178 836 and #212 591) Flux Valve Cord HDC Controller 10-Pin, 10 ft Motor Control Cord #212 591 Flux Hopper Flux Valve Wire Drive Assembly Welding Torch Workpiece Sense Leads* (customer supplied)

14-Pin, 30 ft Welding Power Source Control Cord #178 836 Welding Cable

Welding Cable

Recommended Power Sources

Summit Arc 1000 Summit Arc 1250 #903 530 460 V #903 599 575 V #903 570 400 V, 50/60 Hz Sub Arc DC Series Sub Arc DC 650 Sub Arc DC 800 Sub Arc DC 1000 Sub Arc DC 1250 See Lit. Index No. DC/19.8 #907 338 #907 344 #907 342 #907 343 230/460/575 V, 60 Hz 380/400/440 V, 50/60 Hz w/CE 230/460/575 V, 60 Hz 380/400/440 V, 50/60 Hz w/CE

Ordering Information
Equipment and Options HDC 1500 A HDC 1500 DX Miller Tractor MT 1500 A MT 1500 DX RAD Drive Motors RAD-400 RAD-780 Drive Rolls Flux Handling Equipment Flux Hopper with Valve Flux Recovery Systems Torches OBT 600 OBT 600 Torch Body Extensions #043 923 #043 967 #043 969 #043 973 #043 975 #043 900 #043 981 600 amp, 100% duty cycle, air-cooled 1 inch 2 inch 4 inch 6 inch 1200 amp, 100% duty cycle, air-cooled 9 inch See chart on page 6 #199 733 #195 411 #194 783 #108 008 #119 438 #195 308 #195 342 #043 725 #043 726 #043 727 For 1/167/32 in (1.65.6 mm) wire Provides 6-in travel adjustment, load capacity of 150 lb Provides 6-in travel adjustment, load capacity of 250 lb For 60 lb (27 kg) coil, requires Spool Support Assembly #119 438 Support for 60 lb reels Includes 30 ft (9 m) 14-pin interconnect cable and 10 ft (3 m) motor cable 25 ft (7.6 m) motor cable extension 25 ft (7.6 m), 14-pin 50 ft (15.2 m), 14-pin 75 ft (22.9 m), 14-pin Total Quoted Price: #194 775 25 lb capacity See page 6 #195 265 #195 266 Standard-speed right-angle drive motor High-speed right-angle drive motor See chart on page 6 #951 061 #951 060 With HDC 1500 A analog controller With HDC 1500 DX digital controller Stock No. #300 439 #300 438 Description Qty. Price

OBT 1200 OBT 1200 Torch Body Extension Contact Tips Accessories Wire Straightener Light-Duty Cross Slide Heavy-Duty Cross Slide Wire Reel Spool Support Assembly Cable Kit for HDC 1500 Controllers Motor Extension Cable Extension Cables

Date:

Distributed by:

Litho in USA

Sub Arc DC Series

Heavy Industrial Applications Processes
Submerged Arc (SAW) Air Carbon Arc (CAC-A) Cutting and Gouging Stick (SMAW) Flux Cored (FCAW)

Issued March 2008 Index No. DC/19.8

Submerged Arc Welding Power Source

Input Power Rated Output Weight
3-Phase Power on all models 650/800: 650 A at 44 VDC, 100% Duty Cycle 1000: 1000 A at 44 VDC, 100% Duty Cycle 1250: 1000 A at 44 VDC, 100% Duty Cycle 650/800: 545 lb (247 kg) 1000/1250: 644 lb (292 kg)

Quick Specs

Fabrication and Construction Heavy Manufacturing Pressure Tank/Vessel Fabrication Pipe Welding Shipbuilding Refineries and Foundries Railcar Manufacturing Earth-Moving Equipment Manufacturing

The Power of Blue .

DC multiprocess capability provides versatility and outstanding arc performance in SAW (Submerged Arc) and CC (Stick, Carbon Arc Gouging). Internal digital voltage control (DVC) enables operator to preset weld voltage in the CV mode before striking an arc. Built-in arc control lets you get in tight without sticking the electrode. An electrode compensation circuit ensures consistent arc control performance regardless of the electrode size. Hot Start makes it easier to start difficult-to-start Stick electrodes such as E-6010 and E-7018. Line voltage compensation ensures consistent weld performance by keeping output power constant even if primary input power varies by 10%. Simple control panel features single range amperage/voltage adjustment. Provides easy, efficient operation. Digital voltmeter and ammeter are easy to read, even at 30 ft (9.2 m).

14-pin receptacle provides quick, direct connection to Miller 14-pin wire feeders and accessories. 115 V duplex receptacle provides 15 amps of auxiliary power. Remote on/off capabilities allow operator to turn power source on/off from a distance. Remote voltage control allows operator to change voltage from SAW Control. Power efficient for exceptional value and return on your investment. Fan-On-Demand operates only when needed reducing noise, power consumption, and the amount of airborne contaminants pulled through the machine. Enclosed circuit boards provide additional protection from contaminants resulting in longer service life. Power cord strain relief provided for your convenience at installation.

Sub Arc DC 650

Thermal overload protection light indicates power shutdown. Helps prevent machine damage if the duty cycle is exceeded or airflow is blocked.

Power source is warranted for 3 years, parts and labor. Original main power rectified parts are warranted for 5 years.

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters
Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125

Web Site
www.MillerWelds.com

Sub Arc DC 650/800 Specifications

Model 650 A 800A Rated Output 650 A at 44 VDC, 100% Duty Cycle Amperage/Voltage Range 50 815 A in CC mode 1065 V in CV mode Max. OpenCircuit Voltage* 72 VDC

(Subject to change without notice.)

Amps Input at Rated Output, 50/60 Hz 230 V 380 V 400 V 440 V 460 V 520 V 575 V KVA

KW

Dimensions

Net Weight

126 77 73 66 63 54 50.4 50 34.8 H: 27-1/4 in (692 mm) 545 lb 3.8** 1.9** 1.8** 1.6** 1.9** 1.1** 1.4** 1.52** 0.76** including lift eye (247 kg) W: 22-1/4 in (565 mm) D: 36 in (914 mm) including strain relief

*Open-circuit voltages in CV mode are factory set at values less than indicated for CC.
Certified to both the Canadian and U.S. Standards for welding equipment.

**While idling.

50 Hz models with CE Specifications are manufactured according to the Standard IEC 60974-1.

Control Panel
4
SMAW DIG
SUB ARC

V VOLTS
400 350 CC CV 300 600 250 650 200 700 450 500 550

A AMPS

1
0 100

ARC FORCE

PROCESS

2
ON

A/V
PANEL

150 100 750

3
REMOTE REMOTE

MIN

V A

800 MAX

HIGH TEMP SHUTDOWN

5 6 7
ON

8
A/V ADJUST POWER OFF

OUTPUT

CONTROL

Sub Arc DC 650

CC/CVDC Welding Power Source

MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI 228225 A

1. Arc Force (DIG) Control 2. Remote Amperage/Voltage Control Switch 3. Output Switch (Contactor) 4. Process Selector Switch

5. Digital Meters 6. Amperage/Voltage Adjustment Control 7. High Temperature Shutdown Light 8. Power Switch with Indicator Light

Performance Data
DUTY CYCLE CHART
1000 800 RATED OUTPUT 80 70
MAX.

VOLT/AMP CURVE CV
80
GMAW FCAW

VOLT/AMP CURVE CC
70 60
SMAW

60

WELDING AMPS

DC VOLTS

600

40 30 20 10

MED.

DC VOLTS

50

50 40 30 20
SMAW ARC FORCE SMAW ARC FORCE

400

MIN.

10 0
MIN. MAX. MIN. MAX.

300 40

0 50 60 70 80 90 100 0 100 200 300 400 500 600 700 800 900 1000

0 100 200 300 400 500 600 700 800 900 1000

% DUTY CYCLE

DC AMPS

DC AMPS

Sub Arc DC 1000/1250 Specifications

Model 1000 A 1250 A Rated Output Amperage/Voltage Range 1000 A at 44 VDC, 100 1250 A in CC mode 66 VDC 100% Duty Cycle 1060 V in CV mode

(Subject to change without notice.)

Max. OpenCircuit Amps Input at Rated Output, 50/60 Hz Voltage* 230 V 380 V 400 V 440 V 460 V 575 V KVA

KW

Dimensions

Net Weight

180 109 104 94 90 72 73 53 H: 27-1/4 in (692 mm) 644 lb 5.8** 5.2** 5.0** 4.5** 2.9** 2.4** 3.2** 0.5** including lift eye (292 kg) W: 22-1/4 in (565 mm) D: 36 in (914 mm) including strain relief

*Open-circuit voltages in CV mode are factory set at values less than indicated for CC.
Certified to both the Canadian and U.S. Standards for welding equipment.

**While idling.

50 Hz models with CE Specifications are manufactured according to the Standard IEC 60974-1.

Control Panel
4
SMAW DIG
SUB ARC

V VOLTS
600 500 CC 400 CV 700 800 900

A AMPS

1
0 100

1000 300 1100 200 100 MIN

ARC FORCE

PROCESS

2 3

A/V
ON PANEL

5 6
HIGH TEMP SHUTDOWN

V A

1200 MAX

7
ON

REMOTE

REMOTE

OUTPUT

CONTROL

A/V ADJUST

POWER
OFF
MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI 229210 A

Sub Arc DC 1000

CC/CVDC Welding Power Source

1. Arc Force (DIG) Control 2. Remote Amperage/Voltage Control Switch 3. Output Switch (Contactor) 4. Process Selector Switch

5. Digital Meters 6. Amperage/Voltage Adjustment Control 7. High Temperature Shutdown Light 8. Power Switch with Indicator Light

Performance Data
DUTY CYCLE CHART
2000 1800 1600 1400 80 70
MAX.

VOLT/AMP CURVE CV
Dimension 1000-CV 190 973 80 70 60

VOLT/AMP CURVE CC

WELDING AMPS

1200 1000

60 50

MAX.

50

VOLTS

900 800 700 600 500 10

VOLTS

40 30 20
MIN.

40
MIN.

30 20
MAX. DIG

10 0 20 30 40 50 60 70 80 90 100 0 100 200 300 400 500 600 700 800 900 1000

10 0 0 200 400 600 800 1000 1200 1400 1600

% DUTY CYCLE

AMPS

AMPS

Components and Accessories

RAD Wire Drive Assemblies
Miller offers either standard- or high-speed 115-volt heavy-duty wire drive assemblies. The RAD-400 has a wire feed speed range of 20 400 inches per minute (0.5 10 MPM). The RAD-780 has a wire feed speed range of 30 780 inches per minute (0.7 19.8 MPM). Included adapter plate allows mounting to 2-1/2, 4-1/4, and 4-5/8 inch bolt-hole patterns. RAD-400 #195 265 Standard-speed, right-angle wire drive assembly. RAD-780 #195 266 High-speed, right-angle wire drive assembly.
Included adapter plate allows mounting to 2-1/2, 4-1/4, and 4-5/8 inch bolt hole patterns.

Submerged Arc Torches

Accessories
Wire Straightener #199 733 For RAD-400 (standard-speed) or RAD-780 (high-speed) wire drive assembly. For wires 1/16 7/32 in (1.6 5.6 mm)

OBT 600 #043 923 600 amp, 100 percent duty cycle torch with concentric flux flow nozzle. Can be used with 1/16 7/32 in (1.6 5.5 mm) wire. OBT 600 Torch Body Extensions 1 inch #043 967 2 inch #043 969 4 inch #043 973 6 inch #043 975

Light-Duty Cross Slide #195 411 Allows 6 inches of travel adjustment. Two units can be stacked to provide vertical and horizontal movement. Not recommended for tandem. Heavy-Duty Cross Slide #194 783 One-inch diameter, precision, hardened and ground guide rods provide a perfect path for the sealed linear bushings, and smooth accurate movement of the weld head. Allows for 6 inches of travel adjustment and has a load capacity of 200 lb. Recommended for tandem. Wire Reel #108 008 For 60 lb (27 kg) coil of wire. Requires Spool Support Assembly (#119 438).

Drive Rolls
V Knurled drive rolls for use with hard-shelled cored wires. 1/16 in (1.5 mm) #132 955 5/64 in (2.0 mm) #132 960 3/32 in (2.4 mm) #132 961 7/64 in (2.8 mm) #132 962 1/8 in (3.2 mm) #132 963 5/32 in (3.9 mm) #193 700 3/16 in (4.7 mm) #193 701 7/32 in (5.5 mm) #193 702

OBT 1200 #043 900 1200 amp, 100 percent duty cycle torch with concentric flux flow nozzle. Can be used with 1/16 7/32 in (1.6 5.5 mm) wire. OBT 1200 features a replaceable breakaway adapter end to prevent costly damage should torch run into an obstruction. OBT 1200 Torch Body Extension #043 981 Overall length with extension is 9 in. Actual length of extension is 8-1/2 in.

Spool Support Assembly #119 438 For 60 lb (27 kg) wire reel. Cable Kit for HDC 1500 Controllers #195 308 Includes 30 ft (9 m) 14-pin interconnect cable and 10 ft (3 m) motor cable. Motor Extension Cable #195 342 25 ft (7.6 m) extension for the motor cable. Extension Cables 25 ft (7.6 m) #043 725 50 ft (15 m) #043 726 75 ft (23 m) #043 727 14-pin welding power source control cable. Extends distance between power source and controller.

Torch Contact Tips

Wire Size 1/16 in (1.6 mm) 5/64 in (2.0 mm) 3/32 in (2.4 mm) 7/64 in (2.8 mm) 1/8 in (3.2 mm) 5/32 in (4.0 mm) 3/16 in (4.8 mm) 7/32 in (5.6 mm) OBT 600 #192 700 #192 701 #192 702 #192 703 #192 704 #192 705 #192 706 #192 707 OBT 1200 #192 141 #199 026 #192 142 #200 771 #192 143 #192 144 #192 136 #200 756

Flux Handling Equipment

Flux Hopper with Valve #194 775 Flux hopper with automatic flux valve will carry 25 lb of flux. The opening is sized to allow hook-up of any flux-hopper-mounted recovery system. A slag screen is also provided.

Flux Recovery Systems Weld Engineering 1-508-839-9875 American Vacuum 1-800-321-2849 Invincible 1-800-282-6999

Notes

Notes

Notes

Recommended Power Sources

Summit Arc 1000 Summit Arc 1250 #903 530 460 V, 60 Hz #903 599 575 V, 60 Hz #903 570 400 V, 50/60 Hz Sub Arc DC 650 Sub Arc DC 800 Sub Arc DC 1000 Sub Arc DC 1250 #907 338 #907 344 #907 342 #907 343 230/460/575 V, 60 Hz 380/400/440 V, 50/60 Hz w/CE 230/460/575 V, 60 Hz 380/400/440 V, 50/60 Hz w/CE

Ordering Information
Equipment and Options HDC 1500 A HDC 1500 DX RAD Drive Motors RAD-400 RAD-780 Drive Rolls Flux Handling Equipment Flux Hopper with Valve Flux Recovery Systems Torches OBT 600 OBT 600 Torch Body Extensions #043 923 #043 967 #043 969 #043 973 #043 975 #043 900 #043 981 600 amp, 100% duty cycle, air-cooled 1 inch 2 inch 4 inch 6 inch 1200 amp, 100% duty cycle, air-cooled 9 inch See chart on page 4 #199 733 #195 411 #194 783 #108 008 #119 438 #195 308 #195 342 #043 725 #043 726 #043 727 For 1/167/32 in (1.65.6 mm) wire Provides 6-in travel adjustment, load capacity of 150 lb Provides 6-in travel adjustment, load capacity of 250 lb For 60 lb (27 kg) coil, requires Spool Support Assembly #119 438 Support for 60 lb reels Includes 30 ft (9 m) 14-pin interconnect cable and 10 ft (3 m) motor cable 25 ft (7.6 m) motor cable extension 25 ft (7.6 m), 14-pin 50 ft (15.2 m), 14-pin 75 ft (22.9 m), 14-pin Total Quoted Price: #194 775 25 lb capacity See page 4 #195 265 #195 266 Standard-speed right-angle drive motor High-speed right-angle drive motor See chart on page 4 Stock No. #300 439 #300 438 Description With CE With CE Qty. Price

OBT 1200 OBT 1200 Torch Body Extension Contact Tips Accessories Wire Straightener Cross Slide Heavy-Duty Cross Slide Wire Reel Spool Support Assembly Cable Kit for HDC 1500 Controllers Motor Extension Cable Extension Cables

Date:

Distributed by:

Litho in USA

Miller Tractors
Heavy Industrial Applications Processes
Submerged Arc (SAW)

Issued March 2008 Index No. DC/19.9

Submerged Arc Welding

Wire Feed Speed 20400 IPM (511016 cm/min) Wire Size Range 3/325/32 in (2.4 4.0 mm) Travel Speed 466 IPM (10168 cm/min) Weight 162 lb (73 kg) without flux or wire

Quick Specs

Storage Tank Construction Shipbuilding Bridge Decks Beam Construction Plate Seams

Recommended Miller Power Supplies

Sub Arc DC 650/800 Sub Arc DC 1000/1250 Summit Arc 1000/1250

The Power of Blue .

Designed and built to provide maximum reliability in the toughest conditions. This simple to use self-propelled submerged arc welding tractor can easily connect to Miller AC or DC sub arc power supplies.

Package Includes: Tractor HDC weld controller RAD-400 drive motor 25 lb (11.3 kg) capacity flux hopper with valve Wire reel Torch Remote start/stop control Tractor guide rolls Wire straightener

Available with either HDC 1500 DX (digital) or HDC 1500 A (analog) controller. DX model shown.

Easily accommodates a 60 lb (27 kg) wire reel for fewer wire changeovers.

Heavy-duty, four-wheel, chain-driven trackless operation with rubber wheels provides superior and reliable mobility. Vertical, horizontal and rotary torch adjustment allows for greater access to hard-to-reach spots. Manual clutch enables freewheeling movement of the tractor. Travel speed is precisely controlled by a closed loop microprocessor control with tach feedback.

All of the arms, support posts, etc. can be removed with quick acting clamps enabling the carriage to be totally dismantled without tools and easily passed through an 24 in (610 mm) manhole. Simple and easy changeover from fillet to butt weld configuration.

MT 1500 DX shown.

3 years parts and labor; original main power rectifier parts are warranted for 5 years. Reliability built into each controller.

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters
Phone: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125

Web Site
www.MillerWelds.com

Speed Control Panel

6 1 2 3
IPM CM MIN

Miller Tractor
The Miller Tractor is a highly flexible self-contained welding unit comprised of a travel system and a variety of quality engineered components designed to produce precision, high-quality Submerged Arc welds. Tractor comes complete with a main mounting mast and handle assembly, mounting arm for one wire reel, vertical and horizontal 4 x 4 in slides, control support arm and one set of two adjustable guide roll arms. The friction drive heavy-duty travel carriage utilizes a positive chain drive powering four rubber-tired wheels with a closed-loop tach feedback for accurate speed control. A manual clutch enables freewheeling movement of the carriage. Remote pendant control box houses forward/stop/reverse switch and infinitely variable 4-turn speed potentiometer as well as LED display in IPM or cm/min. Available with either the HDC 1500 DX or 1500 A (see Lit. No. AY/12.0).

7 8 9

10 4 5 11 12 13

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Forward Motion Commanded Indicator Reverse Motion Commanded Indicator Hold (Stop) Mode Active Indicator Auto Enable Mode Manual Carriage Mode Speed and Parameter Display Speed Display Indicator (Calibrated in Inches per Minute) Speed Display Indicator (Calibrated in Centimeters per Minute) Programming Mode Indicator (Flashing) Speed Adjustment Command Forward Motion Neutral Command Reverse Motion

Specifications
Wire Feed Speed Wire Size Range

(Subject to change without notice.)

Max. Incline Gun Positioning Supply Voltage Drive Slides (from HDC 1500) Motor 4 in (101.6 mm) vertical and horizontal stroke 115 VAC, 1-Phase, 50/60 Hz, 200 watts Max. Spool Size Capacity Travel Speed Dimensions* Weight

20 400 IPM 3/32 5/32 in 30 depending (2.4 4.0 mm) on mounting (51 1016 cm/min) configuration

24 VDC 60 lb (27 kg) permanent magnet gear motor

466 IPM H: 43-3/8 in (1102 mm) 162 lb (10 168 D: 35-1/2 in (903 mm) (73 kg) cm/min) without flux/wire

* Note: Width will vary depending on how system is configured.

Ordering Information
Equipment and Options MT 1500 DX MT 1500 A Date: Stock No. #951 060 #951 061 Description With HDC 1500 DX digital controller With HDC 1500 A analog controller Total Quoted Price: Qty. Price

Distributed by:

Litho in USA