Lincoln Electric SUBARC 5 Instructions For Use And Maintenance Manual
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Lincoln Electric SUBARC 5 Instructions For Use And Maintenance Manual

Automatic resurfacing and welding installation by submerged arc
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AUTOMATIC RESURFACING AND WELDING INSTALLATION BY
SUBARC 5
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
EDITION
: EN
REVISION : M
DATE
: 11-2018
SUBMERGED ARC
DX7
Instructions for use
8695 5240
REF:
Original instructions

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Summary of Contents for Lincoln Electric SUBARC 5

  • Page 1 AUTOMATIC RESURFACING AND WELDING INSTALLATION BY SUBMERGED ARC SUBARC 5 SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE 8695 5240 EDITION : EN Instructions for use REF: REVISION : M DATE : 11-2018 Original instructions...
  • Page 2 Thank for the trust you have expressed by purchasing this equipment, which will give you full satisfaction if you follow its instructions for use and maintenance. Its design, component specifications and workmanship comply with applicable European directives. Please refer to the enclosed CE declaration to identify the directives applicable to it.

  • Page 3: Table Of Contents

    4 - COMPOSITION OF A BASIC TWINNED-ARC SUBARC 5 INSTALLATION ..... 12 5 - COMPOSITION OF A BASIC HEAVY-DUTY SINGLE-WIRE SUBARC 5 INSTALLATION 14 6 - COMPOSITION OF A BASIC HEAVY-DUTY TWO-WIRE SUBARC 5 INSTALLATION .. 16 7 - COMPOSITION OF A BASIC HEAVY-DUTY TWINNED-ARC SUBARC 5 INSTALLATION 18 8 - DIMENSIONS ........................
  • Page 4 For operating instructions, adjustments, troubleshooting and spare parts see safety instructions for use and maintenance ISEE No : MOTOVAR MV 20 8695 5832 STARMATIC 1003-1303 DC 8695 5220 STARMATIC 1003-AC/DC 8695 5225 STARMATIC 650 DC 8695 9044 GMR DX7 8695 5235 FLUX POUSSE 8695 5900 D2C SAW 8695 6051 SUBARC 5 - DX7...
  • Page 5 REVISION G 03/10 DESIGNATION PAGE Complete update Mise à jour complète REVISION H 04/12 DESIGNATION PAGE Spare part + Update (DM n°8115) REVISION I 04/14 DESIGNATION PAGE Update REVISION J 07/14 DESIGNATION PAGE Update “D2C SAW” SUBARC 5 - DX7...
  • Page 6 8695 5240 REVISION K 06/15 DESIGNATION PAGE Update D-25 ; F-50 ; F-51 REVISION L 09/16 DESIGNATION PAGE Suppression of adaptation board D - F REVISION M 11/18 DESIGNATION PAGE To change logos SUBARC 5 - DX7...

  • Page 7: A - Identification

    8695 5240 / M A - IDENTIFICATION Please enter the number of your equipment in the following box. Quote this information in all correspondence. Manufacturing factory code Year manufactured Manufacturing year code Product type Product serial no. SUBARC 5 - DX7...

  • Page 8: B - Safety Instructions

    8695 5240 / M B - SAFETY INSTRUCTIONS For general safety instructions, please refer to the specific manual supplied with the equipment. AIRBORNE NOISE Please refer to the specific manual supplied with the equipment. SUBARC 5 - DX7...

  • Page 9: Special Safety Instructions

    - fine particles being emitted into the atmosphere, which might be inhaled, - less effective welding, - powder distributing devices being blocked SUBARC 5 - DX7...
  • Page 10 B - SAFETY INSTRUCTIONS 8695 5240 / M SUBARC 5 - DX7...

  • Page 11: C - Description

     A front panel for adjustments and welding cycle selection. POWER SOURCE ADAPTATION: Includ the accessories for power unit fixation on power source and the connections cables B - CONTROL BOX VERSION SUBARC 5  The control box groups all the controls and visualizations needed by the operator during welding ...
  • Page 12  This unit is a metal box, which can be fixed from behind or below on a 42mm diameter tube using plastic rings. Refer to the instructions for D2C SAW: 8695 6051 SUBARC 5 - DX7...
  • Page 13 C - DESCRIPTION 8695 5240 / M SUBARC 5 - DX7...

  • Page 14: Composition Of A Basic Single-Wire Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 2 - COMPOSITION OF A BASIC SINGLE-WIRE SUBARC 5 INSTALLATION SUBARC 5 - DX7...
  • Page 15 8695 5240 / M Ref. Description Part number SUBARC 5 DX7 SINGLE-WIRE BASE INCLUDING/ - 1 SUBARC 5 DX7 power cabinet W000315694 W000315089 - 1 SUBARC 5 control panel - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.

  • Page 16: Composition Of A Basic Two-Wire Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 3 - COMPOSITION OF A BASIC TWO-WIRE SUBARC 5 INSTALLATION SUBARC 5 - DX7 C-10...
  • Page 17 8695 5240 / M Ref. Description Part number SUBARC 5 DX7 TWIN-WIRE BASE INCLUDING: - 1 SUBARC 5 DX7 power cabinet W000315694 W000315089 - 1 SUBARC 5 control panel - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.

  • Page 18: Composition Of A Basic Twinned-Arc Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 4 - COMPOSITION OF A BASIC TWINNED-ARC SUBARC 5 INSTALLATION SUBARC 5 - DX7 C-12...
  • Page 19 C - DESCRIPTION 8695 5240 / M Ref. Description Part number SUBARC 5 DX7 TWINNED ARC BASE INCLUDING: - 2 SUBARC 5 DX7 power cabinets W000315694 - 2 SUBARC 5 control panels W000315089 - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.

  • Page 20: Composition Of A Basic Heavy-Duty Single-Wire Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 5 - COMPOSITION OF A BASIC HEAVY-DUTY SINGLE-WIRE SUBARC 5 INSTALLATION SUBARC 5 - DX7 C-14...
  • Page 21 C - DESCRIPTION 8695 5240 / M Ref. Description Part number length HEAVY-DUTY SUBARC 5 DX7 SINGLE-WIRE BASE INCLUDING: = 400 mm - 1 SUBARC 5 DX7 power cabinet W000315694 W000315089 - 2 SUBARC 5 control panels - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.

  • Page 22: Composition Of A Basic Heavy-Duty Two-Wire Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 6 - COMPOSITION OF A BASIC HEAVY-DUTY TWO-WIRE SUBARC 5 INSTALLATION SUBARC 5 - DX7 C-16...
  • Page 23 C - DESCRIPTION 8695 5240 / M Ref. Description Part number HEAVY-DUTY SUBARC 5 DX7 TWIN-WIRE BASE INCLUDING: length = 400 mm - 1 SUBARC 5 DX7 power cabinet W000315694 W000315089 - 2 SUBARC 5 control panels - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.

  • Page 24: Composition Of A Basic Heavy-Duty Twinned-Arc Subarc 5 Installation

    C - DESCRIPTION 8695 5240 / M 7 - COMPOSITION OF A BASIC HEAVY-DUTY TWINNED-ARC SUBARC 5 INSTALLATION SUBARC 5 - DX7 C-18...
  • Page 25 C - DESCRIPTION 8695 5240 / M Ref. Description Part number HEAVY-DUTY TWINNED ARCS SUBARC 5 DX7 BASE MADE UP OF: - 1 SUBARC 5 DX7 power cabinet W000315694 W000315089 - 2 SUBARC 5 control panels - 1 control console, D2C SAW (see instructions 8695 6051) length = 17m.
  • Page 26 16-25 mm² universal lug Secondary 1x95 mm² cable (3x17m or 2x22m) to be coupled in parallel for wire W000010142 feeder + 2x10m to be coupled in parallel for the ground W000010640 d18 50-100mm² universal lug SUBARC 5 - DX7 C-20...

  • Page 27: Dimensions

    C - DESCRIPTION 8695 5240 / M 8 - DIMENSIONS Weight = 44.5 Kg CONTROL UNIT VERSION SUBARC 5 PC4-2 Weight of unit alone = 5.250 Kg SUBARC 5 - DX7 C-21...

  • Page 28: D - Assembly Connection

    - Attach the control console near the operator. - Fix the feed head assembly to the machine. Do not forget the plate and the insulating disks. (The latter isolate electrically the wire feed unit which is at the welding potential) SUBARC 5 - DX7 D-22...

  • Page 29: Connection

    CONNECT THE POWER SOURCE: Refer to the instructions of the power source used for connections: STARMATIC 650 DC ISEE N°8695 9044 STARMATIC 1003 AC/DC ISEE N°8695 5225 STARMATIC 1003/1303 DC ISEE N°8695 5220 SUBARC 5 - DX7 D-23...
  • Page 30 D - ASSEMBLY CONNECTION 8695 5240 / M SUBARC 5 - DX7 D-24...
  • Page 31 - Connect the feed wires to terminals L3-L4 and the green/yellow wire to the equipotential connecting copper rod - Adjust coupling of transformers TR1 and TR2 according to the mains voltage. SUBARC 5 - DX7 D-25...
  • Page 32 2 power units using the cable delivered as shown in the diagram below Install the switch delivered with the option on the front panel of the power unit of the AC installation (if necessary, drill the front panel of the unit) SUBARC 5 - DX7 D-26...
  • Page 33 D - ASSEMBLY CONNECTION 8695 5240 / M SUBARC 5 - DX7 D-27...
  • Page 34 D - ASSEMBLY CONNECTION 8695 5240 / M SUBARC 5 - DX7 D-28...
  • Page 35 D - ASSEMBLY CONNECTION 8695 5240 / M SUBARC 5 - DX7 D-29...
  • Page 36 D - ASSEMBLY CONNECTION 8695 5240 / M  For STARMATIC power sources, connect the following wires according to layout.  For other power sources, do not hesitate to contact us. SUBARC 5 - DX7 D-30...
  • Page 37 MACHINE CONNECTION - If you wish to integrate installation to a machine cycle, install a connection between the machine and installation SUBARC 5 connect to J5 of the cycle board (see layout). Pd3-9en EXTERNAL SAFETIES - Two terminals 10 and 11 are available for the connection of the external safety.

  • Page 38: Cycle Board Configuration (Item C6)

    STARMATIC 650 DC +STARMATIC 1003 AC/DC STARMATIC 1003 DC STARMATIC 1303 DC SW8 ..SW11 Slow speed range 0,17 à 4,50 m/mm High speed range 0,6 à 15 m/mm Torch polarity au Torch polarity au – SUBARC 5 - DX7 D-32...
  • Page 39 D - ASSEMBLY CONNECTION 8695 5240 / M SUBARC 5 - DX7 D-33...

  • Page 40: E - Operator Manual

    8695 5240 / M E - OPERATOR MANUAL 1 - FRONT PANEL OF THE POWER UNIT SUBARC 5 - DX7 E-34...
  • Page 41 Power source striking adjustment Selection - Indirect movement start - Movement start with arc established Selection of ignition with the wire - Cold start - Hot start pre-flux or pre-gas timeout post-gas timeout MIG/MAG Selection SAW or MIG/MAG SUBARC 5 - DX7 E-35...

  • Page 42: Control Box

    E - OPERATOR MANUEL 8695 5240 / M 2 - CONTROL BOX SUBARC 5 - DX7 E-36...

  • Page 43: Control Unit, Version D2C Saw

    Welding voltage display unit Wire speed display unit Wire high speed button Button for the initial display of V and A 3 - CONTROL UNIT, VERSION D2C SAW Refer to the instructions for D2C SAW: 8695 6051 SUBARC 5 - DX7 E-37...

  • Page 44: Start-Up On Power Unit

    Check the direction of rotation of the wire feed motor. In order to reverse the direction of rotation : Interchange the motor wires Interchange the wires of the tacho generator.(on SUBARC 5) Adjustment of U and I display units : - Switch off the installation.

  • Page 45: Start-Up Saw Dc And Ac Welding

    Preadjust the cycle end timer pre-fulx timet C 19 Burn off timer Crater filler timer Wire retract timer C12 NOTE : Preadujst C10, C11, C15, C16 with a low value and readjust after the first welding SUBARC 5 - DX7 E-39...

  • Page 46: Preparations Before Welding On Control Unit

    0 and wire feed stops. Pre-adjustment of V and A parameters Press on P12, parameters V and A are displayed Modify P1 and P5 to adjust the required values SUBARC 5 - DX7 E-40...

  • Page 47: Saw Welding Control Of Version Subarc 5

    E - OPERATOR MANUEL 8695 5240 / M 7 - SAW WELDING CONTROL OF VERSION SUBARC 5  Press P6 and keep it pressed in (if you do not want to use pre-flux C19) the flux flows When the flux is sufficient around the point of impact of the wire, release P6 : the welding can start.

  • Page 48: Mig Welding Adjustement

    C15 Adjust the power of the power source on striking by C16 Preadjust the cycle end timer pre-fulx timet C 19 Burn off timer Crater filler timer Wire retract timer C12 post-gas timer C20 SUBARC 5 - DX7 E-42...

  • Page 49: Preparations Before Welding On Control Unit (Mig)

    PREPARATION Make sure that the gas supply is adjusted and in operation 11 - WELDING (MIG) VERSION SUBARC 5  Press P6 and keep it pressed in (if you do not want to use the pre-gas C19)

  • Page 50: F - Maintenance

    "fines" and dust. Dismount and shake well the tissue oversleeve of the flux recycling unit. This operation should be carried out with the installation powered down and after having removed the side panels of the power source. SUBARC 5 - DX7 F-44...

  • Page 51: Troubleshooting

    Defective flux supply. Flux too dirty. Change the flux. Flux supply pipe clogged. Disassemble and clean the flux supply. Flux solenoid valve not Check the power supply of the valve controlled 24v Check fuse : Fu 7 SUBARC 5 - DX7 F-45...
  • Page 52 F - MAINTENANCE 8695 5240 / M SUBARC 5 - DX7 F-46...

  • Page 53: Spare Parts

    Machine interface board   W000XXXXXX Flowmeter   9357 XXXX Silk-screen printed front panel  For parts order, give the quantity required and put the number of your machine in the box below. TYPE: Number: SUBARC 5 - DX7 F-47...
  • Page 54 F - MAINTENANCE 8695 5240 / M SUBARC 5 - DX7 F-48...
  • Page 55 Ref. Stock Order Designation   W000315079 42 V Power transformer   W000315130 Control transformer SUBARC 5 cycle board   W000139859 Speed controler board MOTOVAR MV 20   W000139910   W000139775 100 k potentiometer with button ...
  • Page 56 F - MAINTENANCE 8695 5240 / M SUBARC 5 - DX7 F-50...
  • Page 57 8695 5240 / M  normally in stock  not in stock on request Item Ref. Stock Order Designation SUBARC 5 power unit   W000315089   W000141575 10 k 10-turns potentiometer with button   W000137816 Complete black push-button ...
  • Page 58 F - MAINTENANCE 8695 5240 / M SUBARC 5 - DX7 F-52...
  • Page 59 650 DC/1003 AC/DC  W000260268 Flexible cable 1x95 mm²  W000260268 Flexible cable 1x95 mm²  For parts order, give the quantity required and put the number of your machine in the box below. TYPE: Number: SUBARC 5 - DX7 F-53...

  • Page 60: Personal Notes

    F - MAINTENANCE 8695 5240 / M PERSONAL NOTES Lincoln Electric France S.A.S. Avenue Franklin Roosevelt 76120 Le Grand Quevilly 76121 Le Grand Quevilly cedex www.lincolnelectriceurope.com SUBARC 5 - DX7 F-54...

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