Process
Submerged arc welding (SAW)
SubArc Hercules system
Miller SubArc Hercules System
SubArc Hercules is a high-deposition submerged arc system built around a SubArc power source, XMT 450 SAW Hercules secondary power source, Hercules torch, preheat switch, and Hobart SubCOR wire.
High depositionHercules torchSubCOR wireSwitch kit
Input power
Requires 3-phase power
DC 650 / 800 output
650 A at 44 V, 100% duty cycle
DC 1000 / 1250 output
1,000 A at 44 V, 100% duty cycle
AC/DC output
1,000 A at 44 V, 100% duty cycle
Hercules secondary source
450 A at 10 V, 100% duty cycle
What Makes the Hercules System Different
The Hercules process combines a SubArc power source, a dedicated secondary XMT 450 SAW Hercules source, a two-tip Hercules torch, a preheat switch, and Hobart SubCOR wire. The torch uses separate preheat and welding contact tips to support high-deposition submerged arc welding.
All components are sold separately. No special wire drive or interface is required.
Catalog Components
| Part number | Component | Catalog note |
|---|---|---|
| 907481005 | XMT 450 SAW Hercules power source | Secondary electrical current source for SubArc Hercules; catalog notes this model is for SubArc Hercules only. |
| 301725 | SubArc Hercules torch | Air-cooled torch based on OBT 1200 with two contact tips. |
| 301735 | SubArc Hercules preheat switch | Enable/disable switch with LED. |
| Unknown | SubArc Digital power source | Provides submerged arc welding current. Compatible with SubArc DC 650 Digital, DC 1000 Digital, AC/DC Digital, and legacy 14-pin SubArc equipment. |
| Unknown | SubArc Interface Digital Control | Requires a SubArc control cable to connect the interface to the SubArc Digital power source. |
| Unknown | SubArc Flux Hopper | Includes an 11 ft power cord. |
| 300938 / 301596 | SubArc Wire Drive 400 or 200 Digital Low Voltage | Includes a 4 ft motor control cable. |
| Unknown | Motion control integration | The system can be configured with supplier-integrated mechanized or automated motion control. |
| Unknown | Hobart SubCOR wire | Catalog lists SubCOR EM13K-S MOD, SubCOR 92S, SubCOR N1-S, SubCOR 100F3-S, and SubCOR 120-S. |
Hercules Torch Parts and Wear Items
Use the wire size and the contact-tip position to identify the correct preheat or welding tip. The upper tip is the OBT 600 resistive preheat tip; the lower tip is the OBT 1200 weld tip.
| Part number | Torch part | Catalog fit or note |
|---|---|---|
| 81925 / 49740 | Wire inlet guide | 81925: 1/16-1/8 in.; 49740: 5/32-1/4 in.; qty. 1 each. |
| 291480 | Torch breakaway adapter | SubArc Hercules torch breakaway adapter. |
| 192704 / 192705 | OBT 600 resistive preheat (RP) contact tips | 192704: 1/8 in.; 192705: 5/32 in.; qty. 1 each. |
| 290822 | Top connection assembly | Top connection assembly for the Hercules torch. |
| 290820 | Preheat chambers | Preheat chamber assembly. |
| 290816 | Copper connection point | Copper connection point. |
| 290819 | Preheat ceramic tube | Preheat ceramic tube. |
| 291479 | Extension tip | Extension tip. |
| 192143 / 192144 | OBT 1200 weld contact tips | 192143: 1/8 in.; 192144: 5/32 in.; qty. 1 each. |
| 192135 | Tip nut | Tip nut. |
| 192758 | Nozzle body clamp | Nozzle body clamp. |
| 192137 | Nozzle assembly | Nozzle assembly. |
| 192138 | Nozzle | Nozzle. |
Ordering Information
| Stock number | Item | DC/19.95 note |
|---|---|---|
| 907481005 | XMT 450 SAW Hercules | Dedicated secondary power source; CV only; for SubArc Hercules only. |
| 301725 | SubArc Hercules torch | Air-cooled Hercules torch based on the standard Miller OBT 1200 torch. |
| 301735 | SubArc Hercules switch kit | Enable/disable switch with LED when enabled. |
| Unknown | SubArc Digital Series | See Miller literature AD/7.3 for available SubArc power sources and accessories. |
| 242208025 / 242208050 / 242208080 | 14-pin extension cables | 25 ft, 50 ft, and 80 ft cable options. |
| 192704 / 192705 | OBT 600 resistive preheat contact tips | 1/8 in. and 5/32 in.; qty. 1 each. |
| 192143 / 192144 | OBT 1200 weld contact tips | 1/8 in. and 5/32 in.; qty. 1 each. |
Compatible SubArc Power Sources
SubArc DC 650 Digital
907622 650 A at 44 V, 100% duty cycle
View machineSubArc DC 800 Digital (50 Hz) CE
907623 815 A at 44 V, 60% duty cycle
View machineSubArc DC 1000 Digital
907624 1,000 A at 44 V, 100% duty cycle
View machineSubArc DC 1250 Digital (50 Hz) CE
907625 1,250 A at 44 V, 60% duty cycle
View machineSubArc AC/DC Digital
907620 1,000 A at 44 V, 100% duty cycle
View machineSubArc AC/DC 1250 Digital (50 Hz) CE
907621 1,250 A at 44 V, 60% duty cycle
View machineSeparate Hercules Power Source Page
XMT 450 SAW Hercules
907481005 450 A at 10 V, 100% duty cycle CV only; for SubArc Hercules only.
View power sourceNeed more help?
Fitment note
Confirm whether you are replacing the Hercules torch, the upper OBT 600 preheat tip, the lower OBT 1200 weld tip, or a system cable before ordering.
Source
Miller Electric DC/19.95, SubArc Hercules System, issued May 2025. Related schematics are identified in the sheet as OM-294383A, OM-267533S, OM-296848, and AD/7.3.