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: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
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
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. 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
0
0
20
10
30
40
50
60
70
80
100 200 300 400 500 600 700 800 900 1000
GMAW
FCAW
MAX.
MED.
MIN.
DC AMPS
DC VOLTS
VOLT/AMP CURVE CC
0
0
20
10
30
40
50
60
70
80
100 200 300 400 500 600 700 800 900 1000
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

7
8
1
2
3
6
5
4
A/V
0100
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
PANEL
®
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. 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

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.

5
Notes