Miller HDC 1500A Owner's Manual
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Miller HDC 1500A Owner's Manual

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HDC 1500A
OM-216386V
2016−06−28
Processes
Submerged (SAW) Welding
Description
Submerged Arc Controller For
Automatic Welding
50, 60 Hz
File: SUBMERGED (SAW)

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Summary of Contents for Miller HDC 1500A

  • Page 1 OM-216386V 2016−06−28 Processes Submerged (SAW) Welding Description Submerged Arc Controller For Automatic Welding HDC 1500A 50, 60 Hz For product information, File: SUBMERGED (SAW) Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ..............5-3. Typical Connection Diagram With Miller Power Sources .

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • 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 injure. 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

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

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 12: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

  • Page 14: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Description This weld control is designed to au- tomatically cycle welding events while maintaining constant wire feed speed. This unit can be used with constant current, constant voltage, AC or DC welding power sources. Normally open relay con- tacts that work in conjunction with the weld cycle are available to inter- face with other equipment (such as...

  • Page 15: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Typical Equipment Location Welding Power Source Side Beam Weld Control Spool Support Wire Drive Assembly Automatic Welding Gun Ref. 131 138-A 5-2. Mounting Hole Layout 5/16 in. (7.9 mm) 8 in. Dia. 4 Holes (203 mm) 10-3/4 in.

  • Page 16: Typical Connection Diagram With Miller Power Sources

    5-3. Typical Connection Diagram With Miller Power Sources Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, gun, welding wire, weld cables, remote voltage sense leads and flux system for the desired application.

  • Page 17: Left Side Panel Connections

    5-4. Left Side Panel Connections Receptacle Keyway Access Holes - For Customer Use: Connections To Terminal Strips, Flux Valve, etc. Turn Off welding power source and weld control and disconnect input power be- fore opening access door. Install strain relief (customer supplied) in access hole.

  • Page 18: Terminal Block Tb1 And Tb2 Connections

    5-5. Terminal Block TB1 And TB2 Connections Turn Off welding power source and weld control and disconnect input power be- fore opening access door. Access Door Remove securing screw and open access door. Terminal Block TB2 Terminal Block TB1 Securing Screw - Terminal Block Stripped Lead Typical Lead Being...

  • Page 19: Terminal Block Tb1 Connection Information

    5-6. Terminal Block TB1 Connection Information Terminal/Number Receptacle Location Function Information A on 14-Pin A normally open set of relay contacts connect terminal A to terminal B when Start is pressed and pre-flux timer times out (contacts are rated 10 amperes, 125 volts AC).

  • Page 20: Connection Of 115 Vac Flux Hopper Without Plug

    5-8. Connection Of 115 VAC Flux Hopper Without Plug Turn Off welding power source and weld control and disconnect input power be- fore opening access door. Access Door Four-Conductor Cable Remove securing screw and open From Flux System access door. Terminal Block TB2 Access Hole - (Located in Left Side of Unit) Used For...

  • Page 21: Remote 10 Receptacle Rc2 Information

    5-9. Remote 10 Receptacle RC2 Information Socket Socket Information REMOTE 10 To positive (+) motor armature (115 volts DC motor). To negative (−) motor armature (115 volts DC motor). To motor field. To motor field. Chassis common. Wirefeed Drive Tachometer feedback; 0 to +12 volts DC. Motor Hookups 12 volts DC to power tachometer Circuit common for +12 volts DC circuit.

  • Page 22: Remote 4 Receptacle Rc3 Information

    5-11. Remote 4 Receptacle RC3 Information User Accessible Via TB2 Socket Socket Information Terminal # 115 volts AC to power flux hopper. Black Switched 115 volts AC to power flux hopper. Flux Hopper Hookups White Circuit common for 115 volts AC for flux hopper. Green Chassis common for flux hopper.

  • Page 23: Remote Voltage Sense Leads Placement Guidelines For A Single Arc (Required)

    5-12. Remote Voltage Sense Leads Placement Guidelines For A Single Arc (Required) WELDING POWER Sense lead is affected by weld SOURCE Remote Voltage current. Sense Leads Due to voltage drops across work piece, arc voltage may be low, causing need for deviation from standard procedures.

  • Page 24: Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs

    5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs Lead WELDING POWER Current flow from lead affects trail SOURCE sense. Current flow from trail affects lead sense. Neither sense lead picks up the correct work voltage, causing starting and welding arc instability. Trail Remote Voltage WELDING...

  • Page 25: Recommended Power Sources

    5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs (Continued) Lead WELDING Refer to power source owner’s manual for BEST POWER sense lead connection to terminal strip. SOURCE Both sense leads are out of the current paths. Both sense leads detect arc volt- age accurately.

  • Page 26: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Controls (Use With Section 6-2) Amperage and voltage control limits may be rescaled see Section 6-2. 202 966-G OM-216386 Page 22...

  • Page 27: Description Of Controls (Use With Section 6-1)

    Inch Down switch. To re- the flux valve relay remains energized and Turn switch ON to energize the HDC 1500A tract the wire into the torch, press the Inch Up the weld cycle begins. The weld continues Controller.

  • Page 28: Inside Panel Controls

    For Submerged Arc Welding, this control should be set to zero (0). CC/CV Switch Set this switch to tell the HDC 1500A whether you are using a constant current (CC) or constant voltage (CV) power source in the weld system. In CV mode, the controller feeds wire at a constant rate.

  • Page 29: Section 7 − Maintenance & Troubleshooting

    Turn welding power source and weld control. Supplementary Protector CB1 CB1 protects the HDC 1500A internal circuits from overload. If CB1 opens, all operations stop. Correct the prob- lem, and press button to reset. Ref. 803 022-C OM-216386 Page 25...
  • Page 30 TB1, terminal F, with respect to terminal D (see Section 5-5). HDC 1500A needs a signal of greater than 1 volt DC (i.e. >100 amps) for unit to go from run-in into weld parame- ters.
  • Page 31 7-4. Status/Trouble Light Status/Trouble Light Condition Status/Possible Cause Controller is off. Power switch is in off position. Power source power switch is in the off position. Bad cable connection between power source and HDC controller. Check supplementary protector CB1, and reset if necessary (see Section 7-2). Controller is on.

  • Page 32: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 238 415-B Figure 8-1. Circuit Diagram OM-216 386 Page 28...

  • Page 33: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 803 024-E Figure 9-1. Control Box Components Item Dia. Part Mkgs. Description Quantity Figure 9-1 Main Assembly ... . . 214799 .
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 9-1 Main Assembly ... . . 214805 ..Bracket, Terminal Strip ..........
  • Page 35 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 36 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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