How it Works
Miller Electric
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DC 650
Owner's Manual
52 pgs1.29 Mb0
Owner's Manual
48 pgs1.86 Mb0
User Manual
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Miller Electric DC 650 User Manual

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Page 1
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.
Page 2
0
100
SMAW DIG
V
VOLTS
A
AMPS
MILLER ELECTRIC MFG. CO.,APPLETON, WI
MADE IN
MADE IN
HIGH TEMP SHUTDOWN
A
V
MIN
MAX
800
750
700
650
600
550
500
450
400
350
300
250
100
150
200
CC
CV
SUB ARC
228225 A
PROCESS
A/V
ARC FORCE
CONTROL
A/V ADJUST
POWER
ON
OFF
PANEL
REMOTE
REMOTE
ON
CC/CV• DC Welding Power Source
Sub Arc DC 650
OUTPUT
7
8
1
2
3
6
5
4
Performance Data
2
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. Open­Circuit 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
0
0
20
10
30
40
50
60
70
80
100 200 300 400 500 600 700 800 9001000
GMAW
FCAW
MAX.
MED.
MIN.
DC AMPS
DC VOLTS
VOLT/AMP CURVE CC
0
0
20
10
30
40
50
60
70
80
100 200 300 400 500 600 700 800 9001000
SMAW
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
Page 3
7
8
1
2 3
6
5
4
A/V
0
100
SMAW DIG
ON
REMOTE REMOTE
OUTPUT CONTROL
ARC FORCE PROCESS
A/V ADJUST
V
VOLTS
A
AMPS
ON
OFF
POWER
Sub Arc DC 1000
CC/CV•DC Welding Power Source
229210 A
MILLER ELECTRIC MFG. CO.,APPLETON, WI
MADE INMADE IN
PANE L
®
HIGH TEMP
SHUTDOWN
CC
CV
SUB ARC
A
V
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
0
0
20
10
30
40
50
60
70
80
200 400 600 800 1000 14001200 1600
MAX.
MIN.
MAX. DIG
AMPS
VOLTS
VOLT/AMP CURVE CV
0
0
20
10
30
40
50
60
70
80
Dimension 1000-CV 190 973
100 200 300 400 500 600 700 800 900 1000
MAX.
MIN.
Performance Data
3
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. Open­Circuit 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
Page 4
4
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.
Page 5
5
Notes
Page 6
6
Notes
Page 7
7
Notes
Page 8
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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