Lincoln Electric SUBARC 5 Instructions For Use And Maintenance Manual Download

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8695 5240 / M

F - MAINTENANCE

SUBARC 5 - DX7

F-49



normally in stock



not in stock

on request

Item

Ref.

Stock

Order

Designation

W000315079





42 V Power transformer

W000315130





Control transformer

W000139859





SUBARC 5

cycle board

W000139910





Speed controler board

MOTOVAR MV 20

C10
C11
C12
C19
C20

W000139775





100 k



potentiometer with button

C13
C17
C18
C21

W000139773





Protective switch

C14

W000139785





Switch

C15
C16

W000139774





10 k



potentiometer with button

F18

W000384429





Flux supply distributor assembly
(

SUBARC 5

- 24VAC)



For parts order, give the quantity required and put the number of your machine in the box below.

TYPE:

Number:

Summary of Contents for SUBARC 5

Page 1: ...ATIC RESURFACING AND WELDING INSTALLATION BY SUBMERGED ARC SUBARC 5 DX7 SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE EDITION EN Instructions for use REF 8695 5240 REVISION M DATE 11 2018 Original instructions ...

Page 2: ... Please refer to the enclosed CE declaration to identify the directives applicable to it The manufacturer will not be held responsible where items not recommended by themselves are associated with this product For your safety there follows a non restrictive list of recommendations or requirements many of which appear in the employment code Finally we would ask you kindly to inform your supplier of...

Page 3: ...UBARC 5 INSTALLATION 18 8 DIMENSIONS 21 D ASSEMBLY CONNECTION 22 1 PREREQUISITES TO THE INSTALLATION WITHOUT POWER SOURCE 22 2 INSTALLATION 22 3 CONNECTION 23 4 CYCLE BOARD CONFIGURATION ITEM C6 32 E OPERATOR MANUAL 34 1 FRONT PANEL OF THE POWER UNIT 34 2 CONTROL BOX 36 3 CONTROL UNIT VERSION D2C SAW 37 4 START UP ON POWER UNIT 38 5 START UP SAW DC AND AC WELDING 39 6 PREPARATIONS BEFORE WELDING O...

Page 4: ...nalog or digital should be considered as indicators 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 ...

Page 5: ...GE Complete update REVISION E 10 07 DESIGNATION PAGE Update heavy duty C20 21 22 23 REVISION F 11 08 DESIGNATION PAGE Complete update spareparts newoffer 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 All REVISION J 07 14 DESIGNATION PAGE Update D2C SAW All ...

Page 6: ...8695 5240 IV SUBARC 5 DX7 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 ...

Page 7: ...IDENTIFICATION Please enter the number of your equipment in the following box Quote this information in all correspondence 1 Manufacturing factory code 4 Year manufactured 2 Manufacturing year code 5 Product type 3 Product serial no ...

Page 8: ...B 2 SUBARC 5 DX7 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 ...

Page 9: ...the wire may come out brutally whiplash effect Risk of unwinding when changing an unemptied spool BE CAREFUL with the weight of the spool Put the spool spindle arms back in place after each intervention It is essential that the flux be changed after a maximum of three recyclings If left longer than that there may be serious risks of fine particles being emitted into the atmosphere which might be i...

Page 10: ...B SAFETY INSTRUCTIONS 8695 5240 M B 4 SUBARC 5 DX7 ...

Page 11: ...the external and power supply safeties An electronic part containing the variable speed unit for wire feed the cycle board of the process and the connections of the power source the console and the machine 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 ...

Page 12: ...N D2C The D2C control unit makes it possible to centralise the data process and movement and manage programs 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 ...

Page 13: ...8695 5240 M C DESCRIPTION SUBARC 5 DX7 C 7 ...

Page 14: ...C DESCRIPTION 8695 5240 M C 8 SUBARC 5 DX7 2 COMPOSITION OF A BASIC SINGLE WIRE SUBARC 5 INSTALLATION ...

Page 15: ...5 DX 7 control bundle length 17m W000315696 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 Turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER ELEMENTS D SEE INSTRUCTIONS RELATING TO FEEDER ACCESSORIES 8695 5242 DETAIL OF FLUX DISTRIBUTION AND RECOVERY ELEMENTS F SEE ...

Page 16: ...C DESCRIPTION 8695 5240 M C 10 SUBARC 5 DX7 3 COMPOSITION OF A BASIC TWO WIRE SUBARC 5 INSTALLATION ...

Page 17: ...5 DX 7 control bundle length 17m W000237678 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 Turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER ELEMENTS D SEE INSTRUCTIONS RELATING TO FEEDER ACCESSORIES 8695 5242 DETAIL OF FLUX DISTRIBUTION AND RECOVERY ELEMENTS F SEE ...

Page 18: ...C DESCRIPTION 8695 5240 M C 12 SUBARC 5 DX7 4 COMPOSITION OF A BASIC TWINNED ARC SUBARC 5 INSTALLATION ...

Page 19: ...C 5 DX7 control bundles length 17m W000237678 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 1 turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER ELEMENTS D SEE INSTRUCTIONS RELATING TO FEEDER ACCESSORIES 8695 5242 DETAIL OF FLUX DISTRIBUTION AND RECOVERY ELEMENTS F ...

Page 20: ...C DESCRIPTION 8695 5240 M C 14 SUBARC 5 DX7 5 COMPOSITION OF A BASIC HEAVY DUTY SINGLE WIRE SUBARC 5 INSTALLATION ...

Page 21: ...X 7 control bundle length 17m W000315696 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 1 Turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER DISTRIBUTION AND FLUX RECYCLING ELEMENTS D SEE INSTRUCTIONS FOR HEAVY DUTY ACCESSORIES NO 8695 5248 DETAIL OF FLUX DISTRIBUTIO...

Page 22: ...C DESCRIPTION 8695 5240 M C 16 SUBARC 5 DX7 6 COMPOSITION OF A BASIC HEAVY DUTY TWO WIRE SUBARC 5 INSTALLATION ...

Page 23: ...X 7 control bundle length 17m W000315696 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 1 Turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER DISTRIBUTION AND FLUX RECYCLING ELEMENTS D SEE INSTRUCTIONS FOR HEAVY DUTY ACCESSORIES N 8695 5248 DETAIL OF FLUX DISTRIBUTION...

Page 24: ...C DESCRIPTION 8695 5240 M C 18 SUBARC 5 DX7 7 COMPOSITION OF A BASIC HEAVY DUTY TWINNED ARC SUBARC 5 INSTALLATION ...

Page 25: ...ontrol bundle length 17m W000315696 length 22m W000315693 FASTENING OF THE WELDING HEAD ASSEMBLY TO THE MACHINE A7 1 Turning support tube assembly W000315104 DETAILS OF COMPONENTS OF THE TUBULAR HEAD C SEE INSTRUCTIONS FOR SA TUBULAR HEAD NO 8695 5260 DETAIL OF FEEDER DISTRIBUTION AND FLUX RECYCLING ELEMENTS D SEE INSTRUCTIONS FOR HEAVY DUTY ACCESSORIES N 8695 5248 DETAIL OF FLUX DISTRIBUTION AND ...

Page 26: ...for wire feeder 2x10m to be coupled in parallel for the ground W000101142 d18 50 100mm universal lug W000010640 1300A OPERATION 100 DC G STARMATIC 1303 DC 400 440v power source W000315021 A8 Adaptation for SUBARC STARMATIC 1303DC unit W000315070 4c x 25 mm cable power source supply W000010106 d18 50 100 mm universal lug W000010095 Secondary 1x95 mm cable 3x17m or 2x22m to be coupled in parallel fo...

Page 27: ...8695 5240 M C DESCRIPTION SUBARC 5 DX7 C 21 8 DIMENSIONS Pc3 Weight 44 5 Kg CONTROL UNIT VERSION SUBARC 5 PC4 2 Weight of unit alone 5 250 Kg ...

Page 28: ...A power Have an air pressure supply of 4 to 6 bar 2 INSTALLATION Place the power unit close to the power source taking care not to clog the air admissions 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 ...

Page 29: ... cable with a female connector to the feed motor Connect the cable for arc voltage measurement to the power lead item 4 Connect the welding current cable to the power lead using a cable of sufficient diameter for the welding intensity 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 S...

Page 30: ...D ASSEMBLY CONNECTION 8695 5240 M D 24 SUBARC 5 DX7 ...

Page 31: ...of the power source to J15 of the cycle board for a STARMATIC 800AC Connect the wires of the tacho generator to connector J1 item 8 and 9 shield rep10 of the variable speed unit C7 Connect the control cable of the power source to J2 of the cycle board TRANSFORMER SIDE Connect the wires of the cable of the wire feed motor to terminals 20 and 21 Fit solenoid valve F18 Connect the wires of the soleno...

Page 32: ...tallations of twin arcs with a DC power source and an AC power source connect the 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 ...

Page 33: ...8695 5240 M D ASSEMBLY CONNECTION SUBARC 5 DX7 D 27 ...

Page 34: ...D ASSEMBLY CONNECTION 8695 5240 M D 28 SUBARC 5 DX7 ...

Page 35: ...8695 5240 M D ASSEMBLY CONNECTION SUBARC 5 DX7 D 29 ...

Page 36: ...D ASSEMBLY CONNECTION 8695 5240 M D 30 SUBARC 5 DX7 For STARMATIC power sources connect the following wires according to layout For other power sources do not hesitate to contact us ...

Page 37: ...NE 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 For use disconnect the strap In order to operate the contact must be closed ...

Page 38: ...SUBARC 5 DX7 4 CYCLE BOARD CONFIGURATION ITEM C6 SW8 SW11 STARMATIC 650 DC STARMATIC 1003 AC DC STARMATIC 1003 DC STARMATIC 1303 DC SW7 Slow speed range 0 17 à 4 50 m mm High speed range 0 6 à 15 m mm ST1 Torch polarity au Torch polarity au ...

Page 39: ...8695 5240 M D ASSEMBLY CONNECTION SUBARC 5 DX7 D 33 ...

Page 40: ...8695 5240 M E 34 SUBARC 5 DX7 E OPERATOR MANUAL 1 FRONT PANEL OF THE POWER UNIT ...

Page 41: ... of the characteristics slooping constante C14 Wire diameter selection C15 Wire speed striking adjustment C16 Power source striking adjustment C17 Selection Indirect movement start Movement start with arc established C18 Selection of ignition with the wire Cold start Hot start C19 pre flux or pre gas timeout C20 post gas timeout MIG MAG C21 Selection SAW or MIG MAG ...

Page 42: ...E OPERATOR MANUEL 8695 5240 M E 36 SUBARC 5 DX7 2 CONTROL BOX ...

Page 43: ...ual Flux auto Flux stop during cycle P5 Voltage adjustment welding P6 Welding ON P7 Welding OFF P8 Welding current display unit P9 Welding voltage display unit P10 Wire speed display unit P11 Wire high speed button P12 Button for the initial display of V and A 3 CONTROL UNIT VERSION D2C SAW Refer to the instructions for D2C SAW 8695 6051 ...

Page 44: ...ollowing adjustment Open the console and adjust The display unit of I to 1500 A The display unit of U to 100 0V After the adjustment press the wire feed button then the raising button the values on the display units change Selection of the generator The wire raising button allows you to increment The wire feed button allows you to decrement The ON button makes it possible to validate the choice of...

Page 45: ...nstante Select the type striking by C18 Cold striking Hot striking Do not use with the alternating current generators Select the type of movement start by C17 indirect with contact Adjust the wire speed on striking by 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 NOTE Preadujst...

Page 46: ...sure that the flux reserve into the tank is sufficient to cover totaly the welding lay DOES NOT OPERATE WITH THE ALTERNATING CURRENT GENERATORS If C18 is in position Feed wire to do contact with the workpiece During wire feed the display unit U P9 displays a value as soon as the electric contact with the part is detected the display unit displays 0 and wire feed stops Pre adjustment of V and A par...

Page 47: ...welding INFORMATION Storing the welding parameters It is possible to store the welding parameters by pressing P6 during welding After welding stops the parameters taken into account during the pulse are restituted on the display units Flux It is possible to stop the flux flow before the end of welding by selecting position with P4 TWIN ARCS AC DC Adjust the starts of the two arcs 0 1 0 1 T L arc D...

Page 48: ...re by C14 Select C21 on MIG Select the mode by C13 Drooping Constante Select the type striking by C18 Cold striking Select the type of movement start by C17 indirect with contact Adjust the wire speed on striking by 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 C...

Page 49: ... do not want to use the pre gas C19 the flux flows Release P66 Before welding start the flux flows for the duration of the timeout adjustment by C 19 Once welding is established improve the adjustments of US and IS with potentiometers P1 and P5 Press P7 to stop welding INFORMATION Storing the welding parameters SAW only It is possible to store the welding parameters by pressing P6 during welding A...

Page 50: ...et the wire feed plate the extension joining pieces and the wire straightener Check the wire nozzles for wear Daily Date of maintenance Démonter le couvercle du recyclage flux le retourner et le secouer énergiquement pour évacuer les fines et la poussière Démonter et secouer efficacement la manchette tissu du couvercle de ensemble de recyclage flux Souffler l intérieur de la vannes à flux des tuya...

Page 51: ...y Red led lit up on cycle board No manual and auto cycle Switch off the power supply and switch on again If the led remains lit up change the board Green led switched off on cycle board Check the power supply of the board Check the fuses Fu 5 6 High instability during welding Defective wire drive Tighten the rollers Check wire supply Power source fault See power source instructions Current supply ...

Page 52: ...F MAINTENANCE 8695 5240 M F 46 SUBARC 5 DX7 ...

Page 53: ...rts duly completed Please specify in the Order column the number of parts desired and indicate the type and the serial number of your equipment For items noted on the photos or sketches but not in the tables send a copy of the page concerned highlighting the particular mark For example normally in stock not in stock on request Item Ref Stock Order Designation 1 W000XXXXXX Machine interface board 2...

Page 54: ...F MAINTENANCE 8695 5240 M F 48 SUBARC 5 DX7 ...

Page 55: ...5 cycle board C7 W000139910 Speed controler board MOTOVAR MV 20 C10 C11 C12 C19 C20 W000139775 100 k potentiometer with button C13 C17 C18 C21 W000139773 Protective switch C14 W000139785 Switch C15 C16 W000139774 10 k potentiometer with button F18 W000384429 Flux supply distributor assembly SUBARC 5 24VAC For parts order give the quantity required and put the number of your machine in the box belo...

Page 56: ...F MAINTENANCE 8695 5240 M F 50 SUBARC 5 DX7 ...

Page 57: ...ete black push button P4 W000137817 3 position switch with return to centre P6 W000137823 Complete wihite ligth push button P7 W000137824 Complete red ligth push button P8 W000139829 Current standard display unit I 1999A W000352226 Current display unit I 2000A P9 W000315109 Voltage display unit P10 W000315059 Wire speed display unit For parts order give the quantity required and put the number of ...

Page 58: ...F MAINTENANCE 8695 5240 M F 52 SUBARC 5 DX7 ...

Page 59: ...W000315682 Motor tachy harness length 22 m E4 W000366129 U measurement harness length 17 m W000366121 U measurement harness length 22 m E5 W000366122 Rack power source harness electronic supply 1000 1300 DC W000315070 Rack power source harness electronic supply 1003 1303 DC W000315069 Rack power source harness electronic supply 650 DC 1003 AC DC E6 W000260268 Flexible cable 1x95 mm E7 W000260268 F...

Page 60: ...F MAINTENANCE 8695 5240 M F 54 SUBARC 5 DX7 PERSONAL NOTES Lincoln Electric France S A S Avenue Franklin Roosevelt 76120 Le Grand Quevilly 76121 Le Grand Quevilly cedex www lincolnelectriceurope com ...

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