Miller Electric | MT-18-12 | Welding - Miller Electric

Welding - Miller Electric
Submerged Arc Components
Quick
Specs
Heavy Industrial Applications
Processes
Railcar
Shipbuilding
Heavy Fabrication
Pipe Industry
Pressure Vessel
Submerged Arc (SAW)
Issued June 2009 • Index No. AY/12.0
Submerged
Arc Welding
The Power of Blue .
®
HDC 1500 DX Controller
Sub Arc DC 650
Adaptable DC, CV controller for use in Sub Arc applications.
The powerful Sub Arc DC power sources provide outstanding
versatility, plus the endurance and high amperage output to
handle the biggest heavy industrial applications.
Look no further than Miller to find your industry’s Sub Arc welding
solutions — featuring the flexible HDC 1500 controllers and Sub
Arc DC series! We offer complete systems that can make you
more productive and help lower your weld costs with less power
consumption, increased deposition rates, and faster travel speeds!
3 years — parts and labor; original main power rectifier parts
are warranted for 5 years. Reliability built into each controller.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
HDC 1500 A and 1500 DX Controllers
Internal terminal strip is able
to integrate with positioners,
sidebeams, turning rolls and
other peripheral equipment.
HDC 1500 A (Analog Controller)
Specifications
Controller
HDC 1500 DX (Digital Controller)
(Subject to change without notice.)
Type of Input from
Welding Power Source
Weld Voltage and Amperage
Capacity (DC)
Welding Power Source Type
HDC 1500 A
Single-phase 115 VAC,
3.5 Amps, 50/60 Hz
Constant Current (CC), Constant Voltage (CV),
DC, with Remote Contactor and Output
Control Capabilities
0 – 60 V
0 – 1500 A
HDC 1500 DX
Single-phase 115 VAC,
3.5 Amps, 50/60 Hz
Constant Voltage (CV), DC, with Remote
Contactor and Output Control Capabilities
0 – 100 V
0 – 1500 A
Dimensions
Weight
H: 7 in (178 mm)
W: 11-1/4 in (286 mm)
D: 11-1/2 in (292 mm)
18 lb
(8.2 kg)
(Without CE) certified to both the Canadian and U.S. Standards for welding equipment.
50/60 Hz models with CE Specifications are manufactured according to the Standard IEC-60974-5.
HDC 1500 A and 1500 DX Control Panels
1
2
10
10
20
0
30
VOLTS
40
300
50
60
600
0
900
AMPERES
1200
1500
1
Program
15
Wire Speed
3
4
16
12
9
Pre-Postflow
10
Sequence
Adjust
Setup
17
13
14
MADE
18
11
19
12
13
HDC 1500 A (Analog Controller)
1. Jog Speed
2. Preflux Time 0 –10 Seconds
3. Run-In Speed
4. Crater/Burnback Output
5. Crater Speed
6. Crater Time 0–5 Seconds
7. Burnback Time 0–5 Seconds
8. CC/CV Switch
9. Postflow Time 0–10 Seconds
10. Voltage Meter
2
Amps
Crater
5
7
8
9
Time (sec)
Start
11
6
Volts
2
3
4
5
6
7
8
11. Power Switch
12. Output Control Knob
13. Start Button
14. Stop Button
15. Amperage Meter
16.Wire Feed Speed Control Knob
17. Indicator Light
18. Wire Inch Up
19. Wire Inch Down
14
15
Do not touch live electrical parts.
Disconnect input power before
maintaining or servicing.
Keep all covers, guards, and
panels securely in place.
MADE
HDC 1500 DX (Digital Controller)
1. Program Display
2. Program Push Button
3. Adjust Control
4. Sequence Push Button
5. Upper Display
6. Upper Display Push Button
7. Lower Display
8. Lower Display Push Button
9. Flux Push Button
10. Setup Push Button
11. Start Button
12. Power Switch
13. Stop Button
14. Wire Inch Up
15. Wire Inch Down
Miller Tractor
The Miller Tractor is a highly flexible self-contained welding unit comprised of a travel
system and a variety of quality engineered components designed to produce precision,
high-quality Submerged Arc welds.
Tractor comes complete with a main mounting mast and handle assembly, mounting
arm for one wire reel, vertical and horizontal 4 x 4 in slides, control support arm and
one set of two adjustable guide roll arms.
The friction drive heavy-duty travel carriage utilizes a positive chain drive powering
four rubber-tired wheels with a closed-loop tach feedback for accurate speed control.
A manual clutch enables freewheeling movement of the carriage. Remote pendant
control box houses forward/stop/reverse switch and infinitely variable 4-turn speed
potentiometer as well as LED display in IPM or cm/min. Available with either the
HDC 1500 DX or 1500 A (see page 2).
Package Includes:
Tractor
HDC weld controller
RAD-400 drive motor
25 lb (11.3 kg) capacity
Tractor guide rolls
flux hopper with valve
Remote start/stop
Wire reel
control
OBT 600 Torch
Wire straightener
Note: Order drive rolls and contact tips separately and extension cords of
appropriate length.
Specifications
Wire Feed
Speed
Wire Size
Range
(Subject to change without notice.)
Gun Positioning Supply Voltage
Drive
Slides
(from HDC 1500) Motor
Max. Incline
20 – 400 IPM 3/32 – 5/32 in 30° depending
(2.4 – 4.0 mm) on mounting
(51 –1016
cm/min)
configuration
4 in (101.6 mm)
vertical and
horizontal
stroke
115 VAC,
1-Phase,
50/60 Hz,
200 watts
Max. Spool
Size Capacity
24 VDC
60 lb (27 kg)
permanent
magnet
gear motor
Travel
Speed
Dimensions*
Weight
4–66 IPM H: 43-3/8 in (1102 mm) 162 lb
(10 –168
D: 35-1/2 in (903 mm) (73 kg)
cm/min)
without
flux/wire
*Width will vary depending on how system is configured.
Tractor Speed Control Panel and Line Drawings
6
1
2
3
IPM
CM
MIN
7
8
9
10
1.
2.
3.
4.
5.
4
11
12
5
13
Forward Motion Commanded Indicator
Reverse Motion Commanded Indicator
Hold (Stop) Mode Active Indicator
Auto Enable Mode
Manual Carriage Mode
6. Speed and Parameter Display
7. Speed Display Indicator
(Calibrated in Inches per Minute)
8. Speed Display Indicator
(Calibrated in Centimeters per Minute)
9.
10.
11.
12.
13.
Programming Mode Indicator (Flashing)
Speed Adjustment
Command Forward Motion
Neutral
Command Reverse Motion
3
Sub Arc DC 650/800 and Sub Arc DC 1000/1250 Power Sources
15 amp 115 VAC duplex receptacle allows operators
the flexibility to run grinders, drills, coolers, etc. from
the power source without the need for additional
115 VAC power in the weld area.
DC multiprocess capability, versatility and
outstanding performance in SAW process.
Line voltage compensation keeps welding
parameters constant even when input voltages
change ±10%. Eliminates need to change welding
parameters throughout the day.
Power efficient for exceptional value and return on
your investment.
Fan-On-Demand™ cooling system only works
when needed reducing energy usage and noise.
Digital meters for presetting and monitoring welding
voltage or amperage.
Fully populated terminal strip for sense leads and
remote on/off.
Remote control capability allows operators fine tuning
capability at an extended distance, with the HDC 1500
Controllers.
See Literature Index No. DC/19.8 for additional
information.
Specifications
Model
Rated Output
Sub Arc DC 650 A at 44 VDC,
650/800
100% Duty Cycle
(Subject to change without notice.)
Mode
Amperage/
Voltage Range
Max. OpenCircuit
Voltage*
CC
50 – 815 A
72 VDC
CV
10 – 65 V
126
3.8**
77
73
1.9** 1.8**
66
63
54
50.4
1.6** 1.9** 1.1** 1.4**
66 VDC
180
5.8**
109 104
5.2** 5.0**
94
4.5**
Sub Arc DC 1000 A at 44 VDC, CC
1000/1250 100% Duty Cycle
CV
100 –1250 A
10 – 60 V
Amps Input at Rated Output, 3-Phase, 50/60 Hz
230 V 380 V 400 V 440 V 460 V 520 V 575 V
*Open-circuit voltages in CV mode are factory set at values less than indicated for CC.
90
2.9**
KVA
KW
Dimensions
Weight
50
34.8
H: 27-1/4 in (692 mm)
1.52** 0.76** including lift eye
W: 22-1/4 in (565 mm)
D: 36 in (914 mm)
73
53
3.2** 0.5** including strain relief
72
2.4**
545 lb
(247 kg)
644 lb
(292 kg)
**While idling.
Certified to both the Canadian and U.S. Standards for welding equipment.
50/60 Hz models with CE Specifications are manufactured according to the Standard IEC-60974-1.
Control Panels
4
1. Arc Force (DIG) Control
2. Remote Amperage/Voltage
Control Switch
3. Output Switch (Contactor)
4. Process Switch
5. Digital Meters
6. Amperage/Voltage
Adjustment Control
7. High Temperature
Shutdown Indicator Light
8. Power Switch with
Indicator Light
V VOLTS
SMAW DIG
SUB
ARC
400
450
1
0
CV
650
200
PROCESS
A/V
2
3
600
250
100
ARC FORCE
550
300
CC
750
100
MIN
REMOTE
5
6
700
150
PANEL
ON
A AMPS
500
350
V
A
800
HIGH TEMP
SHUTDOWN
MAX
7
ON
8
REMOTE
OUTPUT
A/V ADJUST
CONTROL
POWER
OFF
Sub Arc DC 650
MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI
CC/CV•DC Welding Power Source
228225 A
4
V VOLTS
SMAW DIG
SUB
ARC
800
500
1
A AMPS
700
600
900
CC
400
0
CV
1000
300
100
ARC FORCE
2
ON
PROCESS
A/V
PANEL
3
OUTPUT
®
Sub Arc DC 1000
CC/CV•DC Welding Power Source
4
200
100
MIN
REMOTE
5
6
7
1100
V
A
1200
MAX
HIGH TEMP
SHUTDOWN
ON
8
REMOTE
CONTROL
A/V ADJUST
POWER
OFF
MADE IN
MILLER ELECTRIC MFG. CO., APPLETON, WI
229210 A
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.
Included adapter plate allows
mounting to 2-1/2, 4-1/4, and
4-5/8 inch bolt hole patterns.
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.
Submerged Arc Torches
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).
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
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 #300 482
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.
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.
Wire Reel
#108 008
For 60 lb (27 kg)
coil of wire.
Requires Spool
Support Assembly
(#119 438).
OBT 1200 Torch Body Extension #043 981
Overall length with extension is 9 in.
Actual length of extension is 8-1/2 in.
Spool Support Assembly #119 438
For 60 lb (27 kg) wire reel.
Torch Contact Tips
Cable Kit for HDC 1500 Controllers
#195 308
Includes 30 ft (9 m) 14-pin interconnect cable
and 10 ft (3 m) motor cable.
Wire Size
1/16 in (1.6 mm)
5/64 in (2.0 mm)
3/32 in (2.4 mm)
7/64 in (2.8 mm)
1/8 in (3.2 mm)
5/32 in (4.0 mm)
3/16 in (4.8 mm)
7/32 in (5.6 mm)
OBT 600
#192 700
#192 701
#192 702
#192 703
#192 704
#192 705
#192 706
#192 707
OBT 1200
#192 141
#199 026
#192 142
#200 771
#192 143
#192 144
#192 136
#200 756
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.
Flux Recovery Systems
Weld Engineering 1-508-842-2224
American Vacuum 1-800-321-2849
Invincible
1-800-282-6999
5
Questions and Answers
Q. Does Miller have a full offering for the Submerged Arc process?
Miller offers weld controllers, wire drive assembly, power sources, flux
hoppers and torches all developed together to offer you the best
performance from a system approach. When used in conjunction with
each other Miller can assure you that these items have been tested
together to optimize their performance.
Q. Can Miller Submerged Arc equipment be used with equipment other
then Miller?
No: Because of the optimized performance that a Miller system offers
we do not recommend mixing other manufacturers power sources,
controllers or wire drive assemblies.
Q. Why do I need to use sense leads?
Sense leads are critical to obtaining correct arc voltage to optimize
the system. When sense leads are not used the system supplies the
pre-set voltage at the studs of the power source, not at the arc. Voltage
drop in the work piece and cables is not accounted for and therefore a
lower voltage than what is preset will be delivered to the arc and can
cause poor arc performance.
Q. Does it really matter where I hook the sense leads up?
Yes: The proper placement of sense leads is as important as using
them. The proper placement is covered in the owner’s manuals of the
power sources and controllers.
Q. Why is the sense lead connection only on the power source now?
This allows the communication between the power source and control
to be faster and more accurate. This also promotes good starts.
Q. Why are the Deltaweld® and Invision™ no longer recommended?
They do not have the capability to hook up sense leads externally for
accurate arc voltage. The power sources mentioned above have a
terminal strip to accommodate this sense lead hookup.
Q. What is a RAD-400 and RAD-780?
The RAD stands for right angle drive and it is Miller’s wire drive
assembly for wire diameters from 1/16 – 1/4 in. The 400 and 780
represent the highest wire feed speed of each motor. The RAD-400 is
recommended for most sub arc applications using wires larger than
5/64 in (2 mm).
Q. Does Miller Electric have fluxes and wire for Submerged Arc welding?
No they do not. Hobart offers a line of wires and fluxes for SAW
Welding which work with the Miller Submerged Arc equipment. If a
flux and wire combination is being used with current equipment, that
same combination can be used with the Miller Electric equipment. If
you are looking for a new flux and wire, or increased deposition is a
consideration, then the Hobart/Tri-Mark consumables should be
considered. Please contact them through your local distributor or call
Hobart at 937-332-5135 and ask for their recommendations.
Q. Can I use the Miller flux hopper with preheated flux?
Yes. We have improved the design of the flux hopper to be able to
accommodate hot flux whether preheated or reclaiming directly after
the weld. The hopper also comes standard with an electric valve that
can be controlled manually or from the controller.
Q. What power sources are recommended to go along with the
Miller controls?
DC Power Sources
Sub Arc DC 650
Sub Arc DC 800
Sub Arc DC 1000
Sub Arc DC 1250
Part Number
#907 338
#907 344
#907 342
#907 343 with CE
Typical Installation
*Sense leads connected
to the power source
are required for
optimal performance.
DC
Welding
Power
Source
Cable Kit #195 308
(Includes #178 836
and #212 591)
14-Pin, 30 ft Welding
Power Source
Control Cord
#178 836
Welding Cable
Welding Cable
HDC
Controller
10-Pin, 10 ft Motor Control Cord
#212 591
Flux
Hopper
Flux
Valve
Wire Drive
Assembly
Welding Torch
Workpiece
Sense Leads* (customer supplied)
6
Flux Valve Cord
Notes
7
Recommended Power Sources
Sub Arc DC Series
See Lit. Index No. DC/19.8
Sub Arc DC 650
Sub Arc DC 800
Sub Arc DC 1000
Sub Arc DC 1250
#907 338
#907 344
#907 342
#907 343
230/460/575 V, 60 Hz
380/400/440 V, 50/60 Hz w/CE
230/460/575 V, 60 Hz
380/400/440 V, 50/60 Hz w/CE
Ordering Information
Equipment and Options
Stock No.
HDC 1500 A
#300 439
HDC 1500 DX
#300 438
Description
Qty.
Miller Tractor
MT 1500 A
#951 061
With HDC 1500 A analog controller
MT 1500 DX
#951 060
With HDC 1500 DX digital controller
RAD-400
#195 265
Standard-speed right-angle drive motor
RAD-780
#195 266
High-speed right-angle drive motor
RAD Drive Motors
Drive Rolls
See chart on page 5
Flux Handling Equipment
Flux Hopper with Valve
#194 775
Flux Recovery Systems
25 lb capacity
See page 5
Torches
OBT 600
#043 923
600 amp, 100% duty cycle, air-cooled
OBT 600 Torch Body Extensions
#043 967
#043 969
#043 973
#043 975
1 inch
2 inch
4 inch
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 5
Accessories
Wire Straightener
#199 733
For 1/16–7/32 in (1.6–5.6 mm) wire
Light-Duty Cross Slide
#195 411
Provides 6-in travel adjustment, load capacity of 150 lb
Heavy-Duty Cross Slide
#300 482
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
#043 726
#043 727
25 ft (7.6 m), 14-pin
50 ft (15.2 m), 14-pin
75 ft (22.9 m), 14-pin
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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