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Summary of Contents for Miller HDC-1500
- Page 1 OM-202 956A April 2002 Processes Submerged (SAW) Welding MIG (GMAW) Welding Description Submerged Arc Controller For Automatic Welding HDC-1500 50, 60 Hz Visit our website at 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.
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Page 3: Table Of Contents
........4-10. Typical Connection Of A Miller Flux Hopper With Automatic 115 VAC To An HDC 1500 . - Page 4 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA HDC–1500...
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Page 5: Section 1 - Safety Precautions - Read Before Using
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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.
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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 4/98 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.
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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 - Definitions (Ce Models Only)
Become trained and read the instructions before working on the machine or welding. 2-2. Manufacturer’s Rating Label For CE Products Only S/N: 50/60 1500 MILLER ELECTRIC MFG. CO., APPLETON, WI USA ST-178 794-A OM-202 956 Page 9... -
Page 14: Symbols And Definitions
2-3. Symbols And Definitions* Amperes Remote Output Hertz Single Phase Rated Welding Volts Input Alternating Current Current Increase/Decrease Percent Circuit Breaker Run In Speed Of Quantity Protective Earth Postflow Timer Preflux Timer Seconds (Ground) Degree Of Start Stop Primary Voltage Protection Rated Supply Conventional Load... -
Page 15: Description
3-2. 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 having remote contactor control and output control capabili- ties. -
Page 16: Mounting Hole Layout
4-2. Mounting Hole Layout 5/16 in (7.9 mm) 8 in Dia. 4 Holes (203 mm) 10-3/4 in (273 mm) 7 in (178 mm)* * Includes front panel knobs 803 021-B 4-3. Rating Label For Non-CE Products Only 50/60 1500 165 746-B OM-202 956 Page 12... -
Page 17: Connection Diagram
4-8). Connect other end of voltage sensing For non-MILLER power sources, Ter- a non–MILLER power source, or when us- lead to the workpiece, and to the torch. OM-202 956 Page 13... -
Page 18: Left Side Panel Connections
4-5. Left Side Panel Connections Receptacle Keyway For Customer Use: Connections To Terminal Strips, Flux Valve, etc. Y Turn Off welding power source and weld control and disconnect input power be- fore opening access door. Route incoming cables through user access hole prior to making connections to internal terminal strips. -
Page 19: Terminal Strip Tb1 Connections
4-6. Terminal Strip TB1 Connections Y 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 Strip TB1 Stripped Lead Lead Being Connected To 1/4 in (6 mm) Securing Screw... -
Page 20: Terminal Strip Tb2 Connections
4-8. Terminal Strip TB2 Connections Y 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 Strip TB2 Stripped Lead Lead Being Connected To Securing Screw Strip 1/4 in (6 mm) insulation off end of lead, insert end into proper loca-... - Page 21 4-10. Typical Connection Of A Miller Flux Hopper With Automatic 115 VAC T0 An HDC 1500 Y 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.
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Page 22: Remote 5 Receptacle Rc2 Information
4-11. Remote 5 Receptacle RC2 Information Socket Socket Information REMOTE 5 To negative (–) motor armature (115 volts DC motor). To positive (+) motor armature (115 volts DC motor). Wirefeed Drive To motor field. Motor Hookups To motor field. Chassis common. 4-12. - Page 23 Notes OM-202 956 Page 19...
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Page 24: Section 5 - Operation
SECTION 5 – OPERATION 5-1. Front Panel Controls For Non CE Models (Use With Section 5-2) POWER OUTPUT WIRE SPEED INCH ST ART 1500 AC/DC–CV/CC A UTOMATIC CONTROLLER INCH STOP W ARNING W ARNING DOWN ELECTRIC SHOCK can kill. Do not touch live electrical parts. -
Page 25: Description Of Controls
G and I of the 14-pin receptacle. When using Stop Switch cycle begins. The weld continues until the this control with a non-MILLER power source, 115 volts AC can be supplied directly Stop button is pressed. Press the Stop button to end the weld cycle. -
Page 26: Front Panel Controls For Ce Models (Use With Section 5-4)
5-3. Front Panel Controls For CE Models (Use With Section 5-4) HDC1500 AC/DC –CV/CC A UTOMATIC CONTROLLER MADE MADE 208 209-A OM-202 956 Page 22... -
Page 27: Description Of Controls
G and I of the 14-pin receptacle. When using Stop Switch cycle begins. The weld continues until the this control with a non-MILLER power source, 115 volts AC can be supplied directly Stop button is pressed. Press the Stop button to end the weld cycle. -
Page 28: Inside Panel Controls
-5. Inside Panel Controls Jog Speed This control sets the speed at which welding wire is advanced out of the weld- ing gun (Inch Down) or retracted into the gun (Inch Up). CE Models Non CE Models Preflux Time This control sets the length of time, 0 to 10 seconds, during which flux will flow be- fore the arc starts. -
Page 29: Section 6 - Maintenance & Troubleshooting
SECTION 6 – MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair or Clean and Replace replace tighten unreadable cracked weld labels. weld terminals. cable. Replace Check Check gas Check cracked 14-pin hose and parts. cord. -
Page 30: Troubleshooting Table
6-3. Troubleshooting Table Trouble Remedy Unit is completely inoperative. Check circuit breaker CB1, and reset if necessary (see Section 6-2). Place Power Switch S1 in On position (see Section 5-1). Wire does not feed during inching. Check 115 volts ac input power and be sure it is energized. Check circuit breaker CB1, and reset if necessary (see Section 6-2). -
Page 31: Section 7 - Electrical Diagram
SECTION 7 – ELECTRICAL DIAGRAM 204 392 Figure 7-1. Circuit Diagram OM-202 956 Page 27... -
Page 32: Section 8 - Parts List
..NAMEPLATE,MILLER HDC 1500 ........ - Page 35 Effective January 1, 2001 (Equipment with a serial number preface of “LB” 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 &...
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Page 36: Owner's Record
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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