Miller Subarc DC 650 Owner's Manual
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Miller Subarc DC 650 Owner's Manual

Miller Subarc DC 650 Owner's Manual

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OM-265 363B
2014−05
Processes
Submerged Arc (SAW) Welding
Description
Arc Welding Power Source
Subarc DC 650/800, 1000/1250
Digital Power Sources
CE
File: Submerged (SAW)
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Subarc DC 650

  • Page 1 OM-265 363B 2014−05 Processes Submerged Arc (SAW) Welding Description Arc Welding Power Source Subarc DC 650/800, 1000/1250 Digital Power Sources 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 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 5 TABLE OF CONTENTS SECTION 8 − PLC OPERATION ............. . 8-1.
  • Page 6 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 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 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 8 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 body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: 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 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 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 12 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES PIECES DE METAL ou DES LES BOUTEILLES peuvent exploser si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 14 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- D Utiliser des pochettes et des boîtes antista- pements de radio−navigation et de com-...

  • Page 15: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 16 OM-265 364 Page 10...

  • Page 17: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com 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 Wear dry insulating gloves.
  • Page 18 A complete Parts List is available at www.MillerWelds.com Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Consult rating label for input power requirements. Safe34 2012−05 Read Owner’s Manual and inside labels for connection points and procedures. Í...

  • Page 19: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperage/Voltage Gas Tungsten Arc Shielded Metal Arc Amperes Control−Panel Welding (GTAW) Welding (SMAW) Gas Metal Arc Temperature Wire Feeder Arc Force (DIG) Welding (GMAW) Output...

  • Page 20: Section 4 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) For All Equipment Covered In This Manual 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 21: Specifications For Subarc Dc Digital Power Sources

    ** This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered. 4-4. SubArc System Compatibility The following accessory models will function with the SubArc DC 650/800 and 1000/1250 digital power sources. The interface will automatically detect the power source and wire drive type connected. Interfaces: 300936 −...

  • Page 22: Duty Cycle And Overheating

    A complete Parts List is available at www.MillerWelds.com 4-5. Duty Cycle And Overheating A. Duty Cycle And Overheating For DC 650/800 Amp Models 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 fan runs.

  • Page 23: Static Characteristics

    A complete Parts List is available at www.MillerWelds.com 4-6. Static Characteristics The static (output) characteristics of the welding power source can be described as drooping during the SAW process. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.

  • Page 24: Selecting A Location

    A complete Parts List is available at www.MillerWelds.com 4-9. Selecting A Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. Movement Line Disconnect Device Locate unit near correct input power supply.

  • Page 25: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 4-11. Electrical Service Guide Elec Serv 2011−08 A. Electrical Service Guide For DC 650/800 Digital 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.

  • Page 26: Placing Jumper Links

    A complete Parts List is available at www.MillerWelds.com 4-12. Placing Jumper Links Disconnect and lockout/tagout input power before installing or moving jumper links. Check input voltage available at site. Jumper Link Label For DC 650 Digital and DC 1000 Digital Machines Jumper Link Label For DC 800 Digital and DC 1250 Digital...
  • Page 27 A complete Parts List is available at www.MillerWelds.com Notes OM-265 363 Page 21...

  • Page 28: Connecting 3-Phase Input Power

    A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 3-Phase Input Power = GND/PE Earth Ground IMPORTANT Input Contactor L1 (U) L2 (V) L3 (W) GND/ PE Earth Ground Tools Needed: 5/32 in. 3/8, 1/2 in. 3/8 in. input3 2012−05 − Ref. 803 766-C / 800 103-C / Ref. 801 116-A OM-265 363 Page 22...
  • Page 29 A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 3-Phase Input Power (Continued) applicable, use lugs of proper amperage Close and secure access door on welding Installation must meet all National capacity and correct hole size. power source. and Local Codes − have only qualified persons make this installation.

  • Page 30: Section 5 − System Connections

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − SYSTEM CONNECTIONS 5-1. Terminal Strip TE2 and Remote Receptacle RC1 Information Function Socket On RC1 Terminal On TE2 Contact Information Electrical Input Power A, B − 24 VAC. Protected by circuit breaker CB2. C, D −...

  • Page 31: Terminal Strip Te1

    A complete Parts List is available at www.MillerWelds.com 5-2. Terminal Strip TE1 Turn Off welding power source and disconnect input power before opening ac- cess door. Access Hole Remove knockout from access hole and install customer supplied strain relief. Route cable connec- tions through the access hole.

  • Page 32: Section 6 − Making Weld Output Connections

    **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-265 363 Page 26...

  • Page 33: Connecting Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 6-2. 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.

  • Page 34: Basic Sub Arc (Saw) Welding

    A complete Parts List is available at www.MillerWelds.com 6-3. Basic Sub Arc (SAW) Welding Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive extension cable, drive rolls, torch, welding wire, weld cables, remote voltage sense leads, flux hopper, flux hopper extension cable, and flux system for the desired application. A.
  • Page 35 A complete Parts List is available at www.MillerWelds.com B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required) Electrode Remote Voltage Sense Lead Work Remote Voltage Sense Lead Wire Drive Welding Power Sense lead is affected by weld Source current.
  • Page 36 A complete Parts List is available at www.MillerWelds.com C. Sensing Leads Placement Guidelines For Multiple Arcs Lead Wire Drive Welding Power Source Wire Electrode Remote Drive Volt Sense Leads Work Current flow from lead affects trail sense. Remote Voltage Sense Leads Lead Current flow from trail affects lead Trail...
  • Page 37 A complete Parts List is available at www.MillerWelds.com D. Basic Sub Arc (SAW) Equipment Connections For DCEN Turn off welding power source and weld control, and disconnect input power be- fore making connections. Use remote voltage sense leads in all applications. Suggested size for remote volt- age sense wire is 12 gauge or larger.

  • Page 38: Connecting Multiple Units

    A complete Parts List is available at www.MillerWelds.com 6-4. Connecting Multiple Units Turn Off welding power source before opening ac- cess door. NOTICE − If there are any ques- tions regarding the paralleling procedure, contact the factory Parallel Connections For Digital 650/800 Machines: before connecting units.

  • Page 39: Section 7 − Power Source Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − POWER SOURCE OPERATION 7-1. Controls PROCESS OUTPUT A/V ADJUST 262 962-B Process Selector Switch Amperage/Voltage Adjustment Control Turn Off power before connecting re- Place switch in position for desired process. mote device.

  • Page 40: Section 8 − Plc Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − PLC OPERATION 8-1. Automation Interface Hardware Configuration (PLC Users Only) Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Follow established pro- cedures regarding the install- ation and removal of lockout/ tagout devices.

  • Page 41: Connection To Plc

    A complete Parts List is available at www.MillerWelds.com 8-2. Connection To PLC The automation interface uses an RJ45 connector to communicate MODBUS RTU over RS485. It is NOT an Ethernet connection! The pin connections are as follows: Table 8-4. Connector Pinout Function RJ45 Pin Circuit...

  • Page 42: Table 8-7. Command Flags (Modbus 101)

    A complete Parts List is available at www.MillerWelds.com Table 8-7. Command Flags (MODBUS 101) Flag Name Bitmask Description Output Enable 0x0001 Enable Weld Output Wire Jog Up 0x0002 Feed Wire Up Wire Jog Down 0x0004 Feed Wire Down Flux On 0x0008 Open Flux Valve Motor CW...

  • Page 43: Table 8-9. Status Flags (Modbus 201)

    A complete Parts List is available at www.MillerWelds.com Table 8-9. Status Flags (MODBUS 201) Flag Name Bitmask Description Valid Arc 0x0001 A valid arc has been detected. Output On 0x0002 The power source output is on. Run In 0x0004 The power source is in Run In. Weld 0x0008 The power source is in the weld state.

  • Page 44: Section 9 − Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − MAINTENANCE AND TROUBLESHOOTING 9-1. SubArc System Help Codes SubArc Interface SubArc Power Source Sta- Fault Description Digital Help Code tus/Trouble Light HELP will dis- Each flash sequence will play in the up- be followed by a one sec- display, ond pause.
  • Page 45 A complete Parts List is available at www.MillerWelds.com 9-1. SubArc System Help Codes (Continued) SubArc Interface SubArc Power Source Sta- Fault Description Digital Help Code tus/Trouble Light HELP will dis- Each flash sequence will play in the up- be followed by a one sec- display, ond pause.

  • Page 46: Routine Maintenance

    A complete Parts List is available at www.MillerWelds.com 9-2. Routine Maintenance Disconnect and lockout/tagout input power before per- forming maintenance or troubleshooting procedures. n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels...

  • Page 47: Troubleshooting Table For Power Source

    A complete Parts List is available at www.MillerWelds.com 9-4. Troubleshooting Table For Power Source Trouble Remedy No weld output; unit completely Place line disconnect device in On position (see Section 4-13). inoperative; power switch light off. Check for open line fuse(s), and replace if open (see Section 4-13). Check for proper input power connections (see Section 4-13).

  • Page 48: Section 10 − Electrical Diagram

    A complete Parts List is available at www.MillerWelds.com SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram For DC 650/800 Models OM-265 363 Page 42...
  • Page 49 A complete Parts List is available at www.MillerWelds.com 262 523-A OM-265 363 Page 43...
  • Page 50 A complete Parts List is available at www.MillerWelds.com Figure 10-2. Circuit Diagram For DC 1000/1250 Models OM-265 363 Page 44...
  • Page 51 A complete Parts List is available at www.MillerWelds.com 262 521-A OM-265 363 Page 45...
  • Page 52 Notes TM-216 869 Page 46 Dynasty 350/700, Maxstar 350/700...
  • Page 53 Notes...
  • Page 54 Notes TM-216 869 Page 48 Dynasty 350/700, Maxstar 350/700...
  • Page 55 Effective January 1, 2014 (Equipment with a serial number preface of ME or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 56 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 2014 Miller Electric Mfg. Co. 2014−01...

This manual is also suitable for:

Subarc dc 1000Subarc dc 800Subarc dc 1250

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