Miller CP/CC-1500P Owner's Manual
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Miller CP/CC-1500P Owner's Manual

Miller CP/CC-1500P Owner's Manual

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CP/CC-1500P
OM 271
049 517G
April 1999
Processes
Air Carbon Arc (CAC-A)
Cutting and Gouging
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Submerged (SAW) Welding
Description
Arc Welding Power Source

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Summary of Contents for Miller CP/CC-1500P

  • Page 1 OM 271 049 517G April 1999 Processes Air Carbon Arc (CAC-A) Cutting and Gouging MIG (GMAW) Welding Flux Cored (FCAW) Welding Submerged (SAW) Welding Description Arc Welding Power Source CP/CC-1500P Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input at Rated Load Output, Three-Phase Amperage Voltage Maximum Rated Welding Range In CC Range In Open-Circuit Output 230 V 380 V 460 V 575 V Mode CV Mode Voltage DC 60 HZ 50 HZ 60 HZ 60 HZ...

  • Page 14: Selecting A Location And Moving The Welding Power Source

    2-4. Selecting A Location And Moving The Welding Power Source 18 in (460 mm) Open Space On Front And Rear For Good Airflow Lifting Eye Use lifting eye to move unit. Lifting Forks If using lifting forks, extend forks out opposite side of unit.

  • Page 15: Overall Dimensions And Base Mounting Hole Layout

    2-5. Overall Dimensions And Base Mounting Hole Layout Inches Millimeters 59-3/4 1518 27-1/4 1168 1-5/8 42-3/4 1086 15/16 25-3/8 21/32 Weight: 1870 lb (848 kg) ST-159 484 2-6. Selecting And Preparing Weld Output Cables Weld Output Cable Determine total cable length in weld circuit and maximum welding am- peres.

  • Page 16: Weld Cable Size

    2-7. Weld Cable Size Total Cable (Copper) Length In Weld Circuit Not Exceeding* 50 ft Or Less 100 ft 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft (15m) (30m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Welding...

  • Page 17: 115 Volts Ac Duplex Receptacle

    2-9. 115 Volts AC Duplex Receptacle 115 Volts AC Duplex Receptacle A total of 15 amperes of 115 volts ac power is shared between the du- plex receptacle and Remote 14 re- ceptacle pin I (see Section 2-11). Circuit breaker CB3 (see Section 4-2) protects the duplex receptacle and the 115 volts portion of the Re- mote 14 receptacle from overload.
  • Page 18 2-11. Remote 14 Receptacle RC4 Information Socket Information on RC4 24 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB4. 24 VOLTS AC Contact closure to A completes 24 volts ac contactor control circuit. Command reference; +10 volts dc. Remote control circuit common.

  • Page 19: Contactor Interlock Connections

    2-13. Contactor Interlock Connections A set of normally-open contacts is provided on the contactor interlock for connecting equipment that re- quires a contact closure for opera- tion. To make connections, proceed as follows: Remove top and right side panel. Strain Relief Connector Equipment Cord Insert cord from equipment through strain relief.

  • Page 20: Positioning Jumper Links

    2-14. Positioning Jumper Links NOTE Single voltage 50 Hz models do not have an input terminal board and jumper links. Check the unit data label for input voltage requirements. Jumper links allow operation on dif- ferent input voltages and are facto- ry set for the highest input voltage.

  • Page 21: Connecting Input Power

    2-15. Connecting Input Power Have only qualified persons make this installation. Remove right side panel. Line Disconnect Device Of Proper Rating Strain Relief Connector Input Conductors Grounding Conductor Select size and length using Sec- tion 2-16. Conductor insulation must comply with national, state, and local electrical codes.

  • Page 22: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Voltmeter Ammeter Pilot Light Power Switch Start Amperage Control Weld Amperage/Voltage Control Remote Amperage/Voltage Switch Constant Voltage (CV)/Con- stant Current (CC) Switch Output (Contactor) Switch 10 24 VAC Overload Circuit Breaker (See Section 4-2) 11 Control Overload Circuit Breaker (See Section 4-2) 12 115 VAC Overload Circuit...

  • Page 23: Ammeter And Voltmeter (Optional)

    3-3. Ammeter And Voltmeter (Optional) Voltmeter Voltmeter displays voltage at the weld output terminals, but not nec- essarily the welding arc due to cable resistance, poor connec- tions, etc. Ammeter Ammeter displays weld amperage output of unit. Ref. ST-049 187-E 3-4.

  • Page 24: Weld Amperage/Voltage Control

    3-6. Weld Amperage/Voltage Control Weld Amperage/Voltage Control Use control as a means of selecting weld output (weld amperage for CC mode, weld voltage for CV mode). This control can be adjusted while welding. Numbers around control are for ref- erence only. 3-7.

  • Page 25: Power Switch And Pilot Light

    3-9. Power Switch And Pilot Light Pilot Light Power Switch Use this switch to turn unit, pilot light, and fans On and Off. Ref. ST-193 899 3-10. Sequence Of Flux Cored Arc Welding (FCAW) Install & Install & Prepare Put On Turn On Feeder Turn On Auxiliary Connect...

  • Page 26: Section 4 - Maintenance & Troubleshooting

    SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Repair or replace Replace Clean and cracked unreadable tighten weld cable labels. weld terminals. and cords 6 Months Sealed Bearings Blow out or vacuum inside.

  • Page 27: Fuses F1, F2, F3, F4, And F5

    4-3. Fuses F1, F3, F4, And F5 Turn Off welding power source and disconnect input power. For fuse F1: The entire control circuit is pro- tected by cartridge-type fuse F1. Should fuse F1 open, weld output would stop. To check or replace F1, proceed as follows: Remove right or left side panel.

  • Page 28: Troubleshooting

    4-4. Troubleshooting Trouble Remedy Completely inoperative. Place line disconnect switch in the On position (see Section 2-15). Check and replace open line fuse(s) (see Section 2-15). Check for proper jumper links positions (see Section 2-14). Check for proper input connections (see Sections 2-14 and 2-15). Check and replace fuse F1, if necessary (see Section 4-3).

  • Page 29: Section 5 - Electrical Diagrams

    SECTION 5 – ELECTRICAL DIAGRAMS SB-195 569 Figure 5-1. Circuit Diagram OM-271 Page 25...

  • Page 30: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. Figure 6-1. Main Assembly OM-271 Page 26...
  • Page 31 Replace Coils At Factory Or Factory Authorized Service Station Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ....081 861 COVER, top ............
  • Page 32 Hardware is common and not available unless listed. 8 – Fig. 6–3 ST-148 399-B Figure 6-2. Panel, Front w/Components OM-271 Page 28...
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Panel, Front w/Components (Fig 6-1 Item 29) ......NAMEPLATE, (order by model and serial number) .
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Enclosure, Circuit Card w/Components (Fig 6-2 Item 8) ..011 622 SWITCH, tgl 3PDT 15A 125VAC ........
  • Page 35 Item Part Description Quantity Figure 6-4. Terminal Assembly, Pri 3ph (Fig 6-1 Item 13) 038 840 093 861 ..601 838 NUT, brs hex .375-16 jam ..........
  • Page 36 Item Dia. Part Mkgs. Description Quantity Figure 6-5. Panel, Rear w/Components (Fig 6-1 Item 21) ..FM1,2 . . . 032 633 . . . MOTOR, cap perm SP 1/4hp 230VAC 1625rpm (230/460 and ......460/575 volt) (consisting of) .
  • Page 39 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 40: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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