Miller HDC 1500A CE Owner’s Manual

OM-216 386D
August 2004
Processes
Submerged (SAW) Welding
Description
Submerged Arc Controller For
Automatic Welding
HDC 1500A
50, 60 Hz
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Label For CE Products Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Typical Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Rating Label For Non-CE Products Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connection Diagram With Miller Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connection Diagram With Non-Miller Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Left Side Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Terminal Block TB1 And TB2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Terminal Block TB1 Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Terminal Block TB2 Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Typical Connection Of A Flux Hopper With Automatic 115 VAC To An HDC 1500 . . . . . . . . . . . . . . . .
5-11. Remote 10 Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls For Non CE Models (Use With Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Front Panel Controls For CE Models (Use With Section 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Description Of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Inside Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Calibrating The HDC 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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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
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
HDC-1500
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
Additional Standards (Writer: Delete additional standards not applicable)
Arc Welding Equipment − Part 2: Liquid Cooling Systems. IEC 60974-2 Ed. 1
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment − Part 7: Torches. IC 60974-7 Ed.1
European Contact:
Telephone:
Fax:
dec_stat_2/04
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290−203
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-216 386 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-216 386 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-216 386 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-216 386 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-216 386 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-216 386 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-216 386 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-216 386 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − DEFINITIONS (CE Models Only)
3-1. Warning Label Definitions
1
1
2
3
4
4
3
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Become trained and read the
instructions before working on
the machine or welding.
3-2. Manufacturer’s Rating Label For CE Products Only
. When using a RAD-400 (Miller
part number 195265) running
at maximum speed and fully
loaded, the HDC-1500 draws
approximately 4 amps.
S/N:
U 1=
I 1=
115 V
4A
1
U2= 60 V I2=1500A
MILLER ELECTRIC
MFG. CO., APPLETON,
50/60 Hz
IP 2X
X
100 %
WI USA
ST-178 794-A
OM-216 386 Page 9
3-3. Symbols And Definitions*
Hz
Hertz
I2
Rated Welding
Current
A
Amperes
Remote
V
Volts
Input
Percent
Circuit Breaker
Increase/Decrease
Of Quantity
Wire Feed Speed
Protective Earth
(Ground)
Postflow Timer
Preflux Timer
Start Time
Start
Stop
Output
Single Phase
Alternating
Current
U1
Primary Voltage
IP
Degree Of
Protection
Line Connection
U2
Conventional Load
Voltage
Rated Supply
X
I1
Duty Cycle
Current
241a Primary
current
On
Off
Wire Feed Inch
Down
Crater Time
Program
Flux
Wire Feed In Up
*Some of these symbols appear on CE models only.
SECTION 4 − SPECIFICATIONS
4-1. Weld Control
Specification
Description
Type Of Input Power From Welding
Power Source
Single-Phase 115 Volts AC, 10 Amperes, 50/60 Hertz
Welding Power Source Type
Constant Current (CC), Constant Voltage (CV), AC Or DC
Welding Processes
Submerged Arc (SAW), And Electro Slag (ESW) Welding
Overall Dimensions Including Knobs,
Receptacles, Etc.
Weld Control — Height: 11.5 in (292 mm); Width: 12.5 in (318 mm); Depth: 7 in (178 mm)
Weight
Weld Control — Net: 25.5 lb (11.6 kg)
Weld Voltage And Amperage
Capacity (AC Or DC)
0 To 60 Volts
0 To 1500 Amperes
OM-216 386 Page 10
4-2. Description
This weld control is designed to automatically 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 contacts that work in conjunction with
the weld cycle are available to interface with other equipment (such as
fixtures and flux valves). See Section 5-7 and 5-9 for connection information on TB2.
For information on the wire drive assembly, see Owner’s Manual supplied with the assembly.
803 021-C
SECTION 5 − INSTALLATION
5-1. Typical Equipment Location
1
2
3
4
5
6
Welding Power Source
Side Beam
Weld Control
Spool Support
Wire Drive Assembly
Automatic Welding Gun
4
3
5
2
1
6
Ref. 131 138-A
OM-216 386 Page 11
5-2. Mounting Hole Layout
8 in
(203 mm)
5/16 in
(7.9 mm)
Dia. 4 Holes
10-3/4 in
(273 mm)
7 in
(178 mm)*
* Includes front panel knobs
803 021-C
5-3. Rating Label For Non-CE Products Only
. When using a RAD-400 (Miller
part number 195265) running
at maximum speed and fully
loaded, the HDC 1500 draws
approximately 4 amps.
115
4
50/60
60
1500
100
165 746-B
OM-216 386 Page 12
5-4. Connection Diagram With Miller Power Sources
Note
Customer must supply the following: power source, wire drive assembly and drive rolls, gun,
welding wire, weld cables, and flux system for the desired application.
Y Turn Off welding power
source and weld control
and disconnect input
power before making
connections.
This unit is supplied with 10-pin
and 14-pin cords. Select the
proper cord and make each of
the connections shown.
Flux Valve
Cord
14-Pin Welding
Power Source
Control Cord
(SAW)
(Optional)
Voltage
Sensing
Cords
10-Pin Motor
Control Cord
Welding Cables
OM-216 386 Page 13
5-5. Connection Diagram With Non-Miller Power Sources
Note
Customer must supply the following: power source, Miller shunt control, power source control
cable, wire drive assembly and drive rolls, gun, welding wire, weld cables, and flux system for
the desired application.
Y Turn Off welding power
source and weld control
and disconnect input
power before making connections.
. For
non-MILLER power
sources, terminal block TB1
is required for hookup (See
Sections 5-7 and 5-8).
A voltage sense lead is required
when using a non−MILLER power source. To connect a voltage
sense lead, route a two conductor lead through user access
hole and connect to terminals of
TB2 (see Section 5-7). Connect
other end of voltage sensing lead
to the workpiece, and to the
torch.
Flux Valve
Cord
Welding Power
Source Control
Cord
(SAW)
Voltage
Sensing
Cords
10-Pin Motor
Control Cord
SHUNT
CONTROL
Welding Cables
OM-216 386 Page 14
5-6. Left Side Panel Connections
1
1
2
3
2
A
C
D
J
K
B
L
N
E
Y Turn Off welding power
source and weld control and
disconnect input power before opening access door.
I
H
M
Receptacle
Keyway
Access Holes - For Customer
Use: Connections To Terminal
Strips, Flux Valve, etc.
G
. Install strain relief (customer
F
supplied) in access hole.
3
Example Receptacle
Route incoming cables through
user access hole prior to making
connections to internal terminal
strips.
4
5
4
5
14-Pin Receptacle:
Connection To Welding Power
Source.
10-Pin Receptacle:
Connection to Wire Drive
Motor
To connect matching interconnecting cord to one of the above
receptacles, align keyway, insert
plug, and tighten threaded collar.
Connect remaining end of cord to
matching receptacle on applicable
equipment.
Ref. 803 022-C
OM-216 386 Page 15
5-7. Terminal Block TB1 And TB2 Connections
Y Turn Off welding power
source and weld control and
disconnect input power before opening access door.
1
Access Door
Remove securing screw and open
access door.
2
3
4
Terminal Block TB2
Terminal Block TB1
Securing Screw - Terminal
Block
Stripped Lead
Typical Lead Being
Connected To Terminal Block
Access Holes - (Located in
Left Side of Unit) Used For
Connections To Terminal
Blocks, Flux Valve, etc.
5
6
7
7
. Install strain relief (customer
supplied) in access hole.
Strip 1/4 in (6 mm) insulation off end
of lead, insert end into proper location on TB1 and TB2. Tighten applicable securing screw.
Close and secure access door.
1
Tools Needed:
2
3
4
1/4 in
(6 mm)
5
6
Ref. 803 699-A
OM-216 386 Page 16
5-8. Terminal Block TB1 Connection Information
Terminal/Number
Receptacle Location
Function Information
A-2
A on 14-Pin
B-4
B 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).
C - 75
C on 14-PIn
Remote command reference from welding power source.
D - 77
D on 14-Pin
Remote circuit common.
E - 76
E on 14-PIn
Output command to welding power source (0 to 10 volts DC).
G - 31
G on 14-PIn
Circuit common for 24 and 115 volts AC circuits.
I - 32
I on 14-PIn
115 volts AC from welding power source, which is present whenever welding
power source is on.
F
F on 14-PIn
Current feedback input (1 volt DC per 100 amperes).
H
H on 14-PIn
Voltage feedback input (1 volt DC per 10 arc volts).
K
K on 14-PIn
Chassis common.
Remote Stop
When connected to remote common, stops HDC 1500.
Remote Jog Down
When connected to remote common, jogs wire down.
Remote Common
Circuit common for remote capabilities.
5-9. Terminal Block TB2 Connection Information
Terminals
Red
Function Information
115 volts AC to power flux hopper.
Black
Switched 115 volts AC to power flux hopper.
White
Circuit common for 115 volts AC for flux hopper.
Green
Chassis common for flux hopper.
Side Beam 1 Relay
Normally open set of contacts* that close when power source contactor energizes after HDC 1500 Start button
is pressed and preflux has timed out. Contacts open again when HDC 1500 Stop button is pressed.
Side Beam 2 Relay
Normally open set of contacts* that close when an arc is established. These contacts are used when you want
the side beam to start moving only after an arc has been established. Contacts open again when HDC 1500
Stop button is pressed.
Remote Start
Remote Jog Up
Remote Program
Remote Sense
When connected to remote common, starts HDC 1500.
When connected to remote common, jogs wire up.
When connected to remote common, reverses direction of motor.
Sense lead inputs.
* NOTE: All contacts are rated 10 amperes, 125 volts AC.
OM-216 386 Page 17
5-10. Typical Connection Of A Flux Hopper With Automatic 115 VAC To An HDC 1500
Y Turn Off welding power
source and weld control and
disconnect input power before opening access door.
1
Four-Conductor Cable
From Flux System
Access Door
Remove securing screw and open
access door.
2
3
Terminal Block TB2
Access Holes - (Located in
Left Side of Unit) Used For
Connections To Terminal
Blocks, Flux Valve, etc.
. Install strain relief (customer
supplied) in access hole.
3
Strip 1/4 in (6 mm) insulation off end
of leads. Insert four-conductor
cables from flux system through access hole, and make connections
as shown.
Close and secure access door.
Tools Needed:
1
2
Four-Conductor Cable
From Flux System
Black Lead
Red Lead
Green Lead
White Lead
Ref. 803 700-A
OM-216 386 Page 18
5-11. Remote 10 Receptacle RC2 Information
Socket
REMOTE 10
Wirefeed Drive
Motor Hookups
Socket Information
A
To positive (+) motor armature (115 volts DC motor).
B
To negative (−) motor armature (115 volts DC motor).
C
To motor field.
D
To motor field.
E
Chassis common.
F
Tachometer feedback; 0 to +12 volts DC.
G
12 volts DC to power tachometer
H
Circuit common for +12 volts DC circuit.
I
Not used.
J
Not used.
10 Pin Motor Cable
Ref. 212 591-A
5-12. Remote 14 Receptacle RC1 Information
Socket
User Accessible
Via TB1
Socket Information
Terminal #
A
A
24 volts AC or 115 volts AC from welding power source (present
whenever power source is On).
B
B
Normally open set of relay contacts connect A to B when Start is
pressed and preflux timer has timed out.
C
C
Remote command reference from power source; +10 volts DC.
D
D
Remote circuit common.
E
E
Output command signal to power source; 0 to +10 volts DC.
F
F
Current feedback input from power source; +1 volt DC per 100 amperes.
H
H
Voltage feedback input from power source; +1 volt DC per 10 arc
volts.
G
G
Circuit common for 24 and 115 volts AC circuits.
I
I
115 volts AC from welding power source (present whenever welding
power source is on). 115 volts AC is present on terminal block TB1
whenever welding power source is on.
K
K
Chassis common.
Contactor Control
Remote Output Control
Amperage/Voltage Feedback
Electrical Input Power
GND
14 Pin Interconnecting Cable
Ref. 178 836
OM-216 386 Page 19
SECTION 6 − OPERATION
6-1. Front Panel Controls For Non CE Models (Use With Section 6-2)
Amperage and voltage control limits
may be rescaled see Section 6-2.
8
1
5
5
6
4
6
4
3
ON
7
3
V
2
7
8
1
9
0
7
3
OFF
POWER
2
8
1
9
0
10
10
2
INCH
UP
START
6
4
INCH
DOWN
STOP
5
MADE
IN
202 966-D
OM-216 386 Page 20
6-2. Description Of Controls
. This section makes reference to Inside
1
Panel Control which are described in
Section 6-5.
Power Switch
Turn switch ON to energize the HDC 1500
Controller. For this unit to operate, 115 volts
AC must be supplied to this controller on pins
G and I of the 14-pin receptacle. When using
this control with a non-MILLER power
source, 115 volts AC can be supplied to terminal strip. Turn switch Off to shut down the
controller.
2 Power Indicator Light
Lights when Power switch is in the On
position.
3
Amperage Control
If using a CC (Constant Current) machine,
this control adjusts amperage. If using a CV
(Constant Voltage) machine, this control adjusts wire speed.
To rescale limits of “Amperage Control”
in CV mode:
. Determine upper and lower limits while
welding.
To set the desired upper limit amperage adjust the amperage control. Press the “STOP”
button then the “INCH UP” button at the same
time for about one second. The upper limit is
now set.
To set the amperage lower limit adjust the amperage control. Press the “STOP” button then
the “INCH DOWN” button at the same time
for about one second. The lower limit is now
set.
The amperage control will now have the low-
er limit at zero on the control and upper limit
will be at maximum on the amperage control.
To rescale again or to return to maximum and
minimum of control follow the same procedure as previously described.
from 0 to 10 seconds with the Preflux Time
control. After this timer times out, the flux
valve relay remains energized and the weld
cycle begins. The weld continues until the
Stop button is pressed.
4
7
Inch Up/ Inch Down Switches
These Inch or Jog switches are momentary
push button switches, which energize only
the drive motor, allowing for a cold wire jog.
The welding wire jogs at the rate set by the
Jog Speed control. To advance the wire out of
the torch, press the Inch Down switch. To retract the wire into the gun, press the Inch Up
switch.
5
6
To rescale limits of “Voltage Control” in
CC mode:
. Determine upper and lower limits while
welding.
Stop Switch
Press the Stop button to end the weld cycle.
Pressing this button initiates the Crater Fill
and Burnback portion of the weld cycle. The
Wire Feed Speed will switch to the speed set
by the Crater Speed control, and the power
source output will switch to the output set by
Crater/Burnback Output control. The length
of time the controller stays in the crater mode
is set by the Crater Time control. Crater time
can be set between 0 and 5 seconds. After
the crater mode times out, the burnback timer
starts. Burnback is the length of time the
welding wire remains electrically energized
after the drive motor stops, and can be set
from 0 to 5 seconds with the Burnback Time
control.
Start Switch
After pressing the Start button, the flux relay,
which is accessible on terminal strip TB2
(see Section 5-7), energizes immediately.
This relay allows the user to activate an external flux valve. Preflux time can be adjusted
Voltage Control
If using a CV (Constant Voltage) machine,
this control adjusts voltage. If using a CC
(Constant Current) machine, this control adjusts wire speed.
To set the desired upper limit voltage adjust
the voltage control. Press the “STOP” button
then the “INCH UP” button at the same time
for about one second. The upper limit is now
set.
To set the voltage lower limit adjust the voltage control. Press the “STOP” button then
the “INCH DOWN” button at the same time
for about one second. The lower limit is now
set.
The voltage control will now have the lower
limit at zero on the control and upper limit will
be at maximum on the voltage control. To rescale again or to return to maximum and minimum of control follow the same procedure as
previously described.
8
Weld Meters
The meters are provided to monitor the welding operation (either AC or DC). They are not
intended for exact voltage or amperage measurements.
OM-216 386 Page 21
6-3. Front Panel Controls For CE Models (Use With Section 6-4)
Amperage and voltage control limits
may be rescaled see Section 6-4.
8
1
5
5
6
4
7
3
6
4
3
7
3
V
2
7
8
1
9
0
2
8
1
9
0
10
10
2
6
4
5
MADE IN
MADE
208 209-D
OM-216 386 Page 22
6-4. Description Of Controls
. This section makes reference to Inside
To rescale again or to return to maximum and
minimum of control follow the same procedure as previously described.
1
4
Panel Control which are described in
Section 6-5.
Power Switch
Inch Up/ Inch Down Switches
Turn switch ON to energize the HDC 1500
Controller. For this unit to operate, 115 volts
AC must be supplied to this controller on pins
G and I of the 14-pin receptacle. When using
this control with a non-MILLER power
source, 115 volts AC can be supplied to terminal strip. Turn switch Off to shut down the
controller.
These Inch or Jog switches are momentary
push button switches, which energize only
the drive motor, allowing for a cold wire jog.
The welding wire jogs at the rate set by the
Jog Speed control. To advance the wire out of
the torch, press the Inch Down switch. To retract the wire into the gun, press the Inch Up
switch.
2
5
Power Indicator Light
Lights when Power switch is in the On
position.
3
Amperage Control
If using a CC (Constant Current) machine,
this control adjusts amperage. If using a CV
(Constant Voltage) machine, this control adjusts wire speed.
To rescale limits of “Amperage Control”
in CV mode:
. Determine upper and lower limits while
welding.
To set the desired upper limit amperage adjust the amperage control. Press the “STOP”
button then the “INCH UP” button at the same
time for about one second. The upper limit is
now set.
To set the amperage lower limit adjust the amperage control. Press the “STOP” button then
the “INCH DOWN” button at the same time
for about one second. The lower limit is now
set.
The amperage control will now have the lower limit at zero on the control and upper limit
will be at maximum on the amperage control.
Start Switch
After pressing the Start button, the flux relay,
which is accessible on terminal strip TB2
(see Section 5-7), energizes immediately.
This relay allows the user to activate an external flux valve. Preflux time can be adjusted
from 0 to 10 seconds with the Preflux Time
control. After this timer times out, the flux
valve relay remains energized and the weld
cycle begins. The weld continues until the
Stop button is pressed.
Voltage Control
If using a CV (Constant Voltage) machine,
this control adjusts voltage. If using a CC
(Constant Current) machine, this control adjusts wire speed.
To rescale limits of “Voltage Control” in
CC mode:
. Determine upper and lower limits while
welding.
Stop Switch
Press the Stop button to end the weld cycle.
Pressing this button initiates the Crater Fill
and Burnback portion of the weld cycle. The
Wire Feed Speed will switch to the speed set
by the Crater Speed control, and the power
source output will switch to the output set by
Crater/Burnback Output control. The length
of time the controller stays in the crater mode
is set by the Crater Time control. Crater time
can be set between 0 and 5 seconds. After
the crater mode times out, the burnback timer
starts. Burnback is the length of time the
welding wire remains electrically energized
after the drive motor stops, and can be set
from 0 to 5 seconds with the Burnback Time
control.
6
7
To set the desired upper limit voltage adjust
the voltage control. Press the “STOP” button
then the “INCH UP” button at the same time
for about one second. The upper limit is now
set.
To set the voltage lower limit adjust the voltage control. Press the “STOP” button then
the “INCH DOWN” button at the same time
for about one second. The lower limit is now
set.
The voltage control will now have the lower
limit at zero on the control and upper limit will
be at maximum on the voltage control. To rescale again or to return to maximum and minimum of control follow the same procedure as
previously described.
8
Weld Meters
The meters are provided to monitor the welding operation (either AC or DC). They are not
intended for exact voltage or amperage measurements.
OM-216 386 Page 23
6-5. Inside Panel Controls
1
CE Models
Jog Speed
This control sets the speed at which
welding wire is advanced out of the welding gun (Inch Down) or retracted into the
gun (Inch Up).
Non CE Models
2
1
Preflux Time
This control sets the length of time, 0 to 10
seconds, during which flux will flow before the arc starts. During this time, only
the flux relay, located on terminal strip
TB2 (see Section 5-7), is active. Note:
Flux relay remains active throughout the
weld cycle.
3
2
Run-In Speed Control
This control sets the wire feed speed between the time the weld cycle begins and
before an arc is established. After arc initiation, the wire feed speed is set by the
front panel Wire Speed control.
4
Crater/Burnback Output Control
Use this control to set the output level of
the power source while the weld cycle is
in the crater fill and burnback modes.
3
5
Crater Speed Control
Use this control to set the wire feed speed
while the weld cycle is in the crater fill
mode.
6
Crater Time Control
This 0 to 5 seconds adjustable control
sets the length of time the weld cycle
stays in the crater fill mode. While in this
mode, the power source output is set by
the Crater/Burnback Output control rather than the front panel Output control.
Also, the wire feed speed is set by the
Crater Speed control rather than the front
panel Wire Speed control.
4
7
5
Burnback Time Control
This 0 to 5 seconds adjustable control allows setting of the time the welding wire
remains electrically energized after the
drive motor stops. The burnback timer
starts after the crater timer times out. By
adjusting the control properly, the wire
neither freezes in the weld puddle nor in
the contact tube of the gun. If the wire
freezes in the puddle, increase the burnback time. If the wire freezes in the contact tube, decrease the burnback time.
6
8
Postflow Time Control
This 0 to 5 seconds adjustable control allows setting of the time the flux relay remains activated after the Stop button is
pressed. For Sub Arc, this control will
most likely be set to zero (0).
7
9
8
9
CC/CV Switch
Set this switch to tell the HDC 1500
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.
Ref. 803 023-B / 202 959 / 202 960 / 208 269 / 208 270
OM-216 386 Page 24
6-6. Calibrating The HDC 1500
1
2
2
3
4
5
6
7
Ref. 803 021-C
. The HDC 1500 controller is calibrated
from the factory.
If using a TRUE RMS meter capable
of operation over a range of 10HZ to
360HZ, calibration must be done with
the power source in DC or balanced
AC.
If using an AC+DC TRUE RMS meter
capable of operation over a range of
10HZ to 360HZ, calibration can be
done with the power source in DC,
balanced AC or unbalanced AC.
This meter will be referred to as “external meter” in the following procedure. If the external meter does not
meet these requirements do not proceed, as the controller will not be calibrated correctly.
Calibration must be done with a load
bank for accurate calibration. Calibration while welding is not recommended and is difficult as the voltage
and amperage may vary sufficiently
to make calibration inaccurate.
2
Adjust Control Knob
Press the START button on the controller.
3
4
Start Button
Stop Button
Adjust the voltage until the external meter
reads approximately 30.0 volts.
5
6
Power Switch
Inch Down Button
7
Inch Up Button
If using sense leads on the HDC 1500, adjust potentiometer P2 on the controller motor board until the external meter reads
matches the controller voltage meter.
Y Turn off power source, controller,
and load bank.
Attach load bank to torch and work.
Adjust load bank setting to handle 600 amperes.
Disconnect wire drive motor from controller
at motor or control.
Set the external meter to read voltage and
place one lead on the torch and one lead on
the work.
Turn on the power source, controller, and
load bank.
Adjust the zeroing screws on the face of
each meter until the meter reads 0 volts
and 0 amps.
. These screws are for zeroing the meters, not for calibration.
1
HDC 1500 Controller
If not using sense leads on the HDC 1500,
adjust potentiometer P4 on the controller
motor board until the external meter reads
matches the controller voltage meter.
Set the external meter to read amperage
and place meter around the weld cable(s).
Adjust the voltage until the external meter
reads approximately 600 amperes.
Adjust potentiometer P3 on the controller
motor board until the external meter
matches the controller amperage meter.
Press the STOP button on the controller.
Turn off power source, controller, and load
bank.
Re−connect the wire drive motor.
Remove load bank.
OM-216 386 Page 25
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
cracked
parts.
Repair or
replace
cracked
weld
cable.
Clean and
tighten
weld
terminals.
Replace
unreadable
labels.
Check
14-pin
cord.
Check gas
hose and
fittings.
Check
gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
OR
Clean
drive
rolls.
7-2. Circuit Breaker CB1
Y Turn Off welding power
source and weld control.
1
Circuit Breaker CB1
CB1 protects the HDC 1500 internal
circuits from overload. If CB1 opens,
all operations stop. Correct the problem, and press button to reset
breaker.
1
Ref. 803 022-C
OM-216 386 Page 26
7-3. Troubleshooting Table
Trouble
Remedy
Unit is completely inoperative.
Check circuit breaker CB1, and reset if necessary (see Section 7-2).
Wire does not feed during inching.
Place Power Switch S1 in On position (see Section 6-1).
Check 115 volts ac input power and be sure it is energized.
Check circuit breaker CB1, and reset if necessary (see Section 7-2).
Jog Speed Control set too low; increase Jog Speed setting (see Section 6-5).
Check wire feed motor, and repair or replace if necessary.
Check Inch Up push buttons PB3 and Inch Down push button PB4, and replace if necessary
(see Section 6-1 and Parts List).
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire feeds wrong direction during inching.
To change direction, add or remove jumper wire connecting Remote Prog to Remote Common.
Wire only feeds down whether Inch
Down or Up button is pressed.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire does not feed after Start button is
pressed (ensure that all wire feed inching functions are operating properly before checking this problem).
Check Start switch PB1, and replace if necessary.
No wire feed speed control with Wire
Speed control during welding, but
speed can be controlled with Run-In
speed control.
Check Output controls R9 and R10, replace if necessary.
Run-In speed control set to low; increase run-in speed (see Section 6-5).
Check current feedback from power source. This signal, +1 volt DC per 100 amperes, can be measured on terminal strip TB1, terminal F, with respect to terminal D (see Section 5-7). HDC 1500 needs
a signal of greater than 1 volt DC (i.e. >100 amps) for unit to go from run-in into weld parameters.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
No contactor control for welding power
source (ensure that welding power
source is working properly and that all
connections are correct).
Check for contact closure from pin A to pin B. This can be measured on terminal strip TB1, terminal
A, with respect to terminal B (see Section 5-7).
No output control for welding power
source.
Check Output controls R9 and R10, replace if necessary.
Check command signal on pin E. This signal can be measured on terminal strip TB1, terminal E, with
respect to terminal D. Signal should go from 0 to voltage of C with respect to D as Output control is
turned from min. to max.
No Crater mode.
Check to be sure Crater Output, Crater Speed, or Crater Time controls are not set to 0.
OM-216 386 Page 27
SECTION 8 − ELECTRICAL DIAGRAM
213 333-C
Figure 8-1. Circuit Diagram
OM-216 386 Page 28
Notes
OM-216 386 Page 29
SECTION 9 − PARTS LIST
. Hardware is common and
23
not available unless listed.
22
20
21
1
3
19
24
2
4
25
4
26
18
17
16
15
14
27
5
6
11
13
12
10
9
8
7
803 024-C
Figure 9-1. Control Box Components
OM-216 386 Page 30
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1 Main Assembly
. . . 1 . . . . . . . . . . 214 799 . . . . . Box, Enclosure HDC Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 214 820 . . . . . Cover, Right Box Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . S1 . . 011 611 . . . . . Switch, Tgl Dpdt 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . R1-10 . 208 399 . . . . . Potentiometer, Std Slot 1T 2W 10K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 5 . . . . . . . . . . 171 007 . . . . . Knob, Pointer 1.670 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 2
. . . 6 . . PB3, 4 . 202 944 . . . . . Switch, Pb Mc No Spst 5A 115VAC (Gray) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . PB2 . . 202 945 . . . . . Switch, Pb Mc No Spst 5A 115VAC (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . PB1 . . 202 946 . . . . . Switch, Pb Mc No Spst 5A 115VAC (Green) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PL . . 163 562 . . . . . Light, Ind Wht Lens 125VAC Snap−In Neon Non−Relampa . . . . . . . . . . . . 1
. . . 10 . . . . A1 . . 202 947 . . . . . Meter, Amp 2 VDC 0−1500 Scale 3.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . V1 . . 202 948 . . . . . Meter, Volt 2 VDC 0− 60 Scale 3.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 214 816 . . . . . Spacer, Terminal Strip Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 212 481 . . . . . Block, Term 30 Amp 13 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . 212 304 . . . . . Label, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 214 805 . . . . . Bracket, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 115 359 . . . . . Cap, Peaked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 17 . . . . . . . . . . 154 339 . . . . . Knob, Pointer .590 Dia X .250 Id W/Mtg Screw Plstc . . . . . . . . . . . . . . . . . 8
. . . 18 . . . . S2 . . 011 770 . . . . . Switch, Tgl 6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 214 818 . . . . . Bracket, Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 214 822 . . . . . Cover, Left Box Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 070 371 . . . . . Blank, Snap−In Nyl 1.093/1.125 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . 213 267 . . . . . XFMR, Control 27.6VA 24V/18V/18V 115 Pri 50/60HZ . . . . . . . . . . . . . . . . 1
. . . 23 . . . CB1 . . 083 432 . . . . . Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . PC1 . . 217 035 . . . . . Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . RC1 . . 094 480 . . . . . Connector, Cir Ms/Met 14Pin Size 20 Rcpt Panel Solder . . . . . . . . . . . . . . 1
. . . 26 . . . RC2 . . 139 268 . . . . . Conn, Circ Ms/Met 10Skt Size 18 Rcpt Panel Solder . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 193 440 . . . . . Switch, Ground Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 202 966 . . . . . Nameplate, Miller HDC 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 202 959 . . . . . Label, Pots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 202 960 . . . . . Label, CC/CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 155 436 . . . . . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 039 116 . . . . . Label, High Voltage Test And Ground Ok . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 217 342 . . . . . Label, Warning Electric Shock Power Still Present (Standard Version) . . 1
. . . . . . . . . . . . . . . . 217 354 . . . . . Label, Warning Electric Shock Wordless (CE Version) . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 386 Page 31
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Notes
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
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
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
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.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/04