Miller Electric Subarc DC 650 User manual

Processes

Submerged Arc (SAW)

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW)

Flux Cored (FCAW)

Heavy Industrial Applications

Fabrication and Construction

Heavy Manufacturing

Pressure Tank/Vessel Fabrication

Pipe Welding

Shipbuilding

Refineries and Foundries

Railcar Manufacturing

Earth-Moving Equipment

Manufacturing

Quick

Specs

Sub Arc DC Series Submerged Arc Welding

Power Source

Issued March 2008 • Index No. DC/19.8

DC multiprocess capability

provides versatility and outstanding

arc performance in SAW

(Submerged Arc) and CC (Stick,

Carbon Arc Gouging).

Internal digital voltage control

(DVC) enables operator to preset

weld voltage in the CV mode before

striking an arc.

Built-in arc control lets you get in

tight without sticking the electrode.

An electrode compensation circuit

ensures consistent arc control

performance regardless of the

electrode size.

Hot Start™ makes it easier to start

difficult-to-start Stick electrodes

such as E-6010 and E-7018.

Line voltage compensation

ensures consistent weld

performance by keeping output

power constant even if primary

input power varies by ±10%.

Simple control panel features single

range amperage/voltage adjustment.

Provides easy, efficient operation.

Digital voltmeter and ammeter are

easy to read, even at 30 ft (9.2 m).

The Power of Blue®

Power source is warranted for 3 years, parts and labor.

Original main power rectified parts are warranted for 5 years.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

Input Power 3-Phase Power on all models

Rated Output 650/800: 650 A at 44 VDC, 100% Duty Cycle

1000: 1000 A at 44 VDC, 100% Duty Cycle

1250: 1000 A at 44 VDC, 100% Duty Cycle

Weight 650/800: 545 lb (247 kg)

1000/1250: 644 lb (292 kg)

Sub Arc DC 650

Thermal overload protection light indicates

power shutdown. Helps prevent machine damage

if the duty cycle is exceeded or airflow is blocked.

14-pin receptacle provides quick,

direct connection to Miller 14-pin

wire feeders and accessories.

115 V duplex receptacle provides

15 amps of auxiliary power.

Remote on/off capabilities allow

operator to turn power source

on/off from a distance.

Remote voltage control allows

operator to change voltage from

SAW Control.

Power efficient for exceptional value

and return on your investment.

Fan-On-Demand™operates only

when needed reducing noise, power

consumption, and the amount of

airborne contaminants pulled

through the machine.

Enclosed circuit boards provide

additional protection from

contaminants resulting in longer

service life.

Power cord strain relief provided

for your convenience at installation.

0100

SMAW DIG

VOLTS

AMPS

MILLER ELECTRIC MFG. CO., APPLETON, WI

MADE IN

HIGH TEMP

SHUTDOWN

MIN MAX

800

750

700

650

600

550

500

450

400

350

300

250

100

150

200

SUB

ARC

228225 A

PROCESS

A/V

ARC FORCE

CONTROL A/V ADJUST POWER

OFF

PANEL

REMOTE

CC/CV•DC Welding Power Source

Sub Arc DC 650

OUTPUT

Performance Data

Control Panel

Sub Arc DC 650/800 Specifications (Subject to change without notice.)

Rated Output

650 A at

44 VDC,

100% Duty

Cycle

Model

650 A

800A

Amperage/Voltage

Range

50 –815 A

in CC mode

10– 65 V

in CV mode

Max. Open-

Circuit

Voltage*

72 VDC

Amps Input at Rated Output, 50/60 Hz

230 V 380 V 400 V 440 V 460 V 520 V 575 V KVA KW

126 77 73 66 63 54 50.4 50 34.8

3.8** 1.9** 1.8** 1.6** 1.9** 1.1** 1.4** 1.52** 0.76**

Dimensions

H: 27-1/4 in (692 mm)

including lift eye

W: 22-1/4 in (565 mm)

D: 36 in (914 mm)

including strain relief

Net

Weight

545 lb

(247 kg)

50 Hz models with CE Specifications are manufactured according to the Standard IEC 60974-1.

Certified to both the Canadian and U.S. Standards for welding equipment.

*Open-circuit voltages in CV mode are factory set at values less than indicated for CC. **While idling.

% DUTY CYCLE

WELDING AMPS

DUTY CYCLE CHART

300

400

600

800

1000

50 60 70 80 90 10040

RATED OUTPUT

DC AMPS

DC VOLTS

VOLT/AMP CURVE CV

100 200 300 400 500 600 700 800 900 1000

GMAW

FCAW

MAX.

MED.

MIN.

DC AMPS

DC VOLTS

VOLT/AMP CURVE CC

100 200 300 400 500 600 700 800 900 1000

SMAW

ARC FORCE

MIN. MAX.

SMAW

ARC FORCE

MIN. MAX.

1. Arc Force (DIG) Control

2. Remote Amperage/Voltage Control Switch

3. Output Switch (Contactor)

4. Process Selector Switch

5. Digital Meters

6. Amperage/Voltage Adjustment Control

7. High Temperature Shutdown Light

8. Power Switch with Indicator Light

A/V

0100

SMAW DIG

REMOTE REMOTE

OUTPUT CONTROL

ARC FORCE PROCESS

A/V ADJUST

VOLTS

AMPS

OFF

POWER

Sub Arc DC 1000

CC/CV•DC Welding Power Source

229210 A

MILLER ELECTRIC MFG. CO., APPLETON, WI

MADE INMADE IN

PANEL

HIGH TEMP

SHUTDOWN

SUB

ARC

MIN MAX

800

900

1000

1100

1200

700

600

500

400

300

100

200

Control Panel

1. Arc Force (DIG) Control

2. Remote Amperage/Voltage Control Switch

3. Output Switch (Contactor)

4. Process Selector Switch

5. Digital Meters

6. Amperage/Voltage Adjustment Control

7. High Temperature Shutdown Light

8. Power Switch with Indicator Light

% DUTY CYCLE

WELDING AMPS

DUTY CYCLE CHART

500

600

700

800

900

1600

1000

1200

1400

1800

2000

20 30 40 50 60 9070 80 10010

AMPS

VOLTS

VOLT/AMP CURVE CC

200 400 600 800 1000 14001200 1600

MAX.

MIN.

MAX. DIG

AMPS

VOLTS

VOLT/AMP CURVE CV

80 Dimension 1000-CV 190 973

100 200 300 400 500 600 700 800 900 1000

MAX.

MIN.

Performance Data

Sub Arc DC 1000/1250 Specifications (Subject to change without notice.)

Rated Output

1000 A at 44 VDC,

100% Duty Cycle

Amperage/Voltage

Range

100– 1250 A in CC mode

10– 60 V in CV mode

Max. Open-

Circuit

Voltage*

66 VDC

Amps Input at Rated Output, 50/60 Hz

230 V 380 V 400 V 440 V 460 V 575 V KVA KW

180 109 104 94 90 72 73 53

5.8** 5.2** 5.0** 4.5** 2.9** 2.4** 3.2** 0.5**

Dimensions

H: 27-1/4 in (692 mm)

including lift eye

W: 22-1/4 in (565 mm)

D: 36 in (914 mm)

including strain relief

Net

Weight

644 lb

(292 kg)

*Open-circuit voltages in CV mode are factory set at values less than indicated for CC. **While idling.

50 Hz models with CE Specifications are manufactured according to the Standard IEC 60974-1.

Certified to both the Canadian and U.S. Standards for welding equipment.

Model

1000 A

1250 A

Components and Accessories

RAD Wire Drive Assemblies

Miller offers either standard- or high-speed

115-volt heavy-duty wire drive assemblies.

The RAD-400 has a wire feed speed range of

20 – 400 inches per minute (0.5 –10 MPM). The

RAD-780 has a wire feed speed range of

30 – 780 inches per minute (0.7 –19.8 MPM).

Included adapter plate allows mounting to

2-1/2, 4-1/4, and 4-5/8 inch bolt-hole patterns.

RAD-400

#195 265

Standard-speed,

right-angle wire

drive assembly.

RAD-780

#195 266

High-speed,

right-angle wire

drive assembly.

Drive Rolls

“V” Knurled drive rolls for use

with hard-shelled cored wires.

1/16 in (1.5 mm) #132 955

5/64 in (2.0 mm) #132 960

3/32 in (2.4 mm) #132 961

7/64 in (2.8 mm) #132 962

1/8 in (3.2 mm) #132 963

5/32 in (3.9 mm) #193 700

3/16 in (4.7 mm) #193 701

7/32 in (5.5 mm) #193 702

Flux Handling Equipment

Flux Hopper with Valve

#194 775

Flux hopper with automatic

flux valve will carry 25 lb of

flux. The opening is sized

to allow hook-up of any

flux-hopper-mounted

recovery system. A slag

screen is also provided.

Flux Recovery Systems

Weld Engineering 1-508-839-9875

American Vacuum 1-800-321-2849

Invincible 1-800-282-6999

Submerged Arc Torches

OBT 600 #043 923

600 amp, 100 percent duty cycle torch with

concentric flux flow nozzle. Can be used with

1/16 – 7/32 in (1.6 – 5.5 mm) wire.

OBT 600 Torch Body Extensions

1 inch #043 967

2 inch #043 969

4 inch #043 973

6 inch #043 975

OBT 1200 #043 900

1200 amp, 100 percent duty cycle torch with

concentric flux flow nozzle. Can be used with

1/16 –7/32 in (1.6 – 5.5 mm) wire. OBT 1200

features a replaceable breakaway adapter end to

prevent costly damage should torch run into an

obstruction.

OBT 1200 Torch Body Extension #043 981

Overall length with extension is 9 in. Actual

length of extension is 8-1/2 in.

Torch Contact Tips

Wire Size OBT 600 OBT 1200

1/16 in (1.6 mm) #192 700 #192 141

5/64 in (2.0 mm) #192 701 #199 026

3/32 in (2.4 mm) #192 702 #192 142

7/64 in (2.8 mm) #192 703 #200 771

1/8 in (3.2 mm) #192 704 #192 143

5/32 in (4.0 mm) #192 705 #192 144

3/16 in (4.8 mm) #192 706 #192 136

7/32 in (5.6 mm) #192 707 #200 756

Accessories

Wire Straightener #199 733

For RAD-400 (standard-speed) or RAD-780

(high-speed) wire drive assembly.

For wires 1/16 –7/32 in (1.6 – 5.6 mm)

Light-Duty Cross Slide #195 411

Allows 6 inches of travel adjustment. Two units

can be stacked to provide vertical and horizontal

movement.

Not recommended for tandem.

Heavy-Duty Cross Slide #194 783

One-inch diameter, precision, hardened and

ground guide rods provide a perfect path for

the sealed linear bushings, and smooth

accurate movement of the weld head. Allows for

6 inches of travel adjustment and has a load

capacity of 200 lb.

Recommended for tandem.

Wire Reel

#108 008

For 60 lb (27 kg) coil of

wire. Requires Spool

Support Assembly

(#119 438).

Spool Support Assembly #119 438

For 60 lb (27 kg) wire reel.

Cable Kit for HDC 1500 Controllers

#195 308

Includes 30 ft (9 m) 14-pin interconnect cable

and 10 ft (3 m) motor cable.

Motor Extension Cable #195 342

25 ft (7.6 m) extension for the motor cable.

Extension Cables

25 ft (7.6 m) #043 725

50 ft (15 m) #043 726

75 ft (23 m) #043 727

14-pin welding power source control cable.

Extends distance between power source

and controller.

Included adapter plate allows

mounting to 2-1/2, 4-1/4, and

4-5/8 inch bolt hole patterns.

Notes

Litho in USA

Distributed by:

Ordering Information

Equipment and Options Stock No. Description Qty. Price

HDC 1500 A #300 439 With CE

HDC 1500 DX #300 438 With CE

RAD Drive Motors

RAD-400 #195 265 Standard-speed right-angle drive motor

RAD-780 #195 266 High-speed right-angle drive motor

Drive Rolls See chart on page 4

Flux Handling Equipment

Flux Hopper with Valve #194 775 25 lb capacity

Flux Recovery Systems See page 4

Torches

OBT 600 #043 923 600 amp, 100% duty cycle, air-cooled

OBT 600 Torch Body Extensions #043 967 1 inch

#043 969 2 inch

#043 973 4 inch

#043 975 6 inch

OBT 1200 #043 900 1200 amp, 100% duty cycle, air-cooled

OBT 1200 Torch Body Extension #043 981 9 inch

Contact Tips See chart on page 4

Accessories

Wire Straightener #199 733 For 1/16–7/32 in (1.6–5.6 mm) wire

Cross Slide #195 411 Provides 6-in travel adjustment, load capacity of 150 lb

Heavy-Duty Cross Slide #194 783 Provides 6-in travel adjustment, load capacity of 250 lb

Wire Reel #108 008 For 60 lb (27 kg) coil, requires Spool Support Assembly #119 438

Spool Support Assembly #119 438 Support for 60 lb reels

Cable Kit for HDC 1500 Controllers #195 308 Includes 30 ft (9 m) 14-pin interconnect cable and 10 ft (3 m) motor cable

Motor Extension Cable #195 342 25 ft (7.6 m) motor cable extension

Extension Cables #043 725 25 ft (7.6 m), 14-pin

#043 726 50 ft (15.2 m), 14-pin

#043 727 75 ft (22.9 m), 14-pin

Date: Total Quoted Price:

Recommended Power Sources

Summit Arc™1000 #903 530 460 V, 60 Hz

#903 599 575 V, 60 Hz

Summit Arc™1250 #903 570 400 V, 50/60 Hz

Sub Arc DC 650 #907 338 230/460/575 V, 60 Hz

Sub Arc DC 800 #907 344 380/400/440 V, 50/60 Hz w/CE

Sub Arc DC 1000 #907 342 230/460/575 V, 60 Hz

Sub Arc DC 1250 #907 343 380/400/440 V, 50/60 Hz w/CE

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