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OM-236 684 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som _2007

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Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! 

 Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or  severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D

Do not touch live electrical parts.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on

unit.

D

Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

D

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D

Always verify the supply ground 

 check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D

When making input connections, attach proper grounding conduc-

tor first 

 double-check connections.

D

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D

Frequently inspect input power cord for damage or bare wiring 

replace cord immediately if damaged 

 bare wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or poorly spliced cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D

Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type

welding power sources after removal of input

power.

D

Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on gun or

torch.

D

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

Содержание Subarc DC 650

Страница 1: ...Processes Description Multiprocess Welding Arc Welding Power Source OM 236 684D 2008 08 Subarc DC 650 800 Visit our website at www MillerWelds com File Submerged SAW Submerged SAW Welding...

Страница 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Страница 3: ...late Safety Symbols 12 3 5 Symbols And Definitions 13 SECTION 4 INSTALLATION 14 4 1 Specifications 14 4 2 Duty Cycle And Overheating 14 4 3 Volt Ampere Curves 15 4 4 Selecting A Location 16 4 5 Dimens...

Страница 4: ...t Subarc DC 800 conforms to the following Directives and Standards Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392...

Страница 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Страница 6: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Страница 7: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Страница 8: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Страница 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes...

Страница 10: ...de protection Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La proje...

Страница 11: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Страница 12: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Страница 13: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Страница 14: ...OM 236 684 Page 10...

Страница 15: ...ur head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away f...

Страница 16: ...ide label double check all connections jumper link positions and input voltage before applying power S 179 290 1 4 5 3 2 V A V 3 1 96 1 2 3 4 5 6 8 7 9 3 3 Electric Shock And Airflow Label S 179 563 1...

Страница 17: ...e Low In ductance Weld Output Terminal Negative Weld Output Terminal Input On Off Percent Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connectio...

Страница 18: ...4 1 4 50 1 52 34 8 0 76 10 65 V In CV Mode 70 66 VDC In CV Mode While idling Indicates specification differences for CE models 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes t...

Страница 19: ...e Curves Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown High inductance connection A CC Mode B CV Mod...

Страница 20: ...ermine input power needs Label located under front access door 4 Rating Label Typical CE Models Only Use rating label to determine input power needs Label located on rear access door 5 Line Disconnect...

Страница 21: ...801 530 Front Dimensions A 30 in 762 mm Including lift eye B 23 in 584 mm C 38 in 965 mm Including strain relief D 35 in 889 mm E 1 1 4 in 32 mm F 21 1 8 in 537 mm G 1 1 8 in 29 mm H 7 16 in 11 mm Dia...

Страница 22: ...4 volts ac portion of RC8 and Remote Power On Off from overload Press button to reset protector Ref 800 166 C 3 1 2 4 8 Weld Output Terminals Turn Off power before connectingto weld output ter minals...

Страница 23: ...0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 700 4 0 2 2 0 2 3 0 2 4 0 3...

Страница 24: ...lt age sense wire is 12 gauge or larger For better performance for most Sub Arc SAW applica tions make connections to the high inductance weld output terminal Polarity For DCEP Reverse Polarity connec...

Страница 25: ...emote control Turn on welding power source flux system wire drive assembly and HDC Sub Arc controller When Control switch is in Remote position Adjust control does not function Set desired preset volt...

Страница 26: ...nse leads detect arc voltage ac curately Best starts arcs and most reliable results BAD Sense lead is affected by weld current Due to voltage drops across work piece arc voltage may be low causing nee...

Страница 27: ...g need for deviation from standard procedures BAD Current flow from lead affects trail sense Current flow from trail affects lead sense Neither sense lead picks up the correct work voltage causing sta...

Страница 28: ...onnections For better performance for most gas shielded FCAW DCEP applications it is recommended that weld output connections be made to the Low Inductance weld output ter minal Make connections as sh...

Страница 29: ...10 volts dc input command signal from remote control F Current feedback 1 volt per 100 amperes H Voltage feedback 1 volt per 10 arc volts 115 VOLTS AC I I 115 volts 15 amperes 60 Hz ac Protected by su...

Страница 30: ...Off and disconnect in put power before opening terminal strip cover 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain Relief Customer Supplied Secure cord in strain relief Reinstall and secure access...

Страница 31: ...e a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to...

Страница 32: ...Ground Current Sensor Optional Connect green or green yellow grounding conductor to welding power source groundingterminal first If unit is equipped with optional ground current sensor route grounding...

Страница 33: ...ad 0 zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant Voltage position voltmeter dis plays preset...

Страница 34: ...2 Fuse F1 Ref ST 800 101 C Disconnect and lockout tag out input power before checking or changing fuse 1 Fuse F1 See Parts List For Rating Fuse F1 protects control transform er from overload If F1 ope...

Страница 35: ...t connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 Check position of Remote Amperage Voltage Control swit...

Страница 36: ...OM 236 684 Page 32 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Страница 37: ...OM 236 684 Page 33 228 467 B...

Страница 38: ...34 SECTION 8 PARTS LIST 804 628 A Figure 8 1 Main Assembly 650 Model Illustrated Hardware is common and not available unless listed 30 29 22 28 27 24 23 4 3 22 1 21 20 19 18 17 14 16 15 13 12 11 10 9...

Страница 39: ...18 Fig 8 4 PANEL rear w components 1 19 F1 156 065 FUSE crtg 5A 600V time delay 1 20 W 160 794 CONTACTOR def prp 75A 3P 24VAC 1 21 CR4 140 750 SWITCH reed 1 22 217 136 LABEL warning electric shock 2 2...

Страница 40: ...UIT CARD control 50Hz 1 PLG1 158 720 CONNECTOR SOCKETS see Fig 8 3 PLG3 169 240 CONNECTOR SOCKETS 1 PLG4 148 439 CONNECTOR SOCKETS 1 PLG5 152 249 CONNECTOR SOCKETS 1 PLG16 158 719 CONNECTOR SOCKETS 1...

Страница 41: ...218 ID brs 1 27 038 887 STUD pri bd brs 10 32 x 1 375 1 28 CR2 116 592 RELAY encl 24VDC 3PDT 1 29 PC2 232 116 CIRCUIT CARD ASSY display w program 1 PLG10 153 501 CONNECTOR SOCKETS 1 PLG11 148 439 CON...

Страница 42: ...091 THYRISTOR SCR 865A 300V hockey puck 6 6 166 667 CLAMP spring thyristor rectifier 5 500 3 PLG1 158 720 CONNECTOR SOCKETS 1 TP3 192 673 THERMOSTAT rectifier 1 TP6 192 674 THERMOSTAT rectifier 1 802...

Страница 43: ...NNECTOR clamp cable 1 250 1 8 602 177 SCREW set 250 20 x 250knrlpt sch stl 2 10 124 274 BRACKET mtg fan motor 1 11 R3 097 459 RESISTOR WW fxd 375W 20 ohm 1 12 FM 237 398 MOTOR 1 12HP 230V 1550 RPM 50...

Страница 44: ...Notes...

Страница 45: ...Notes...

Страница 46: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Страница 47: ...ns and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate...

Страница 48: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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