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OM-212 296 Page 12

SECTION 5

−

INSTALLATION

5-1. Typical Equipment Location

Ref. 131 138-A

1

Welding Power Source

2

Side Beam

3

Weld Control

4

Spool Support

5

Wire Drive Assembly

6

Automatic Welding Gun

1

2

6

3

4

5

5-2. Mounting Hole Layout

Ref. 803 021-B

8 in

(203 mm)

10-3/4 in

(273 mm)

7 in

(178 mm)*

* Includes front panel knobs

5/16 in

Dia. 4 Holes

(7.9 mm)

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Содержание HDC 1500DX CE

Страница 1: ...50 60 Hz Processes Description OM 212 296S 2009 03 Submerged SAW Welding Submerged Arc Controller For Automatic Welding HDC 1500DX File SUBMERGED SAW Visit our website at www MillerWelds com CE...

Страница 2: ...tinue 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...

Страница 3: ...ler Power Sources 13 5 4 Left Side Panel Connections 14 5 5 Terminal Block TB1 And TB2 Connections 15 5 6 Terminal Block TB1 Connection Information 16 5 7 Terminal Block TB2 Connection Information 16...

Страница 4: ...LE OF CONTENTS SECTION 10 MAINTENANCE TROUBLESHOOTING 33 10 1 Routine Maintenance 33 10 2 Circuit Breaker CB1 33 SECTION 11 ELECTRICAL DIAGRAM 36 SECTION 12 PARTS LIST 38 OPTIONS AND ACCESSORIES WARRA...

Страница 5: ...500 DX 300438 Council Directives S 2006 95 EC Low Voltage S 2004 108 EC Electromagnetic Compatibility S 2006 42 EEC Machinery Directive Standards S IEC 60974 1 Arc Welding Equipment Welding Power Sour...

Страница 6: ......

Страница 7: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Страница 8: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Страница 9: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Страница 10: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Страница 11: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes...

Страница 12: ...de protection Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La proje...

Страница 13: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Страница 14: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Страница 15: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Страница 16: ...tart Stop U1 Primary Voltage IP Degree Of Protection X Duty Cycle I1 Rated Supply Current Line Connection U2 Conventional Load Voltage On Off Wire Feed Inch Down Wire Feed In Up Crater Time Program Fl...

Страница 17: ...th 7 in 178 mm Weight Weld Control Net 25 5 lb 11 6 kg Weld Voltage And Amperage Capacity AC Or DC 0 To 100 Volts 0 To 1500 Amperes 4 2 Description This weld control is designed to au tomatically cycl...

Страница 18: ...Ref 131 138 A 1 Welding Power Source 2 Side Beam 3 Weld Control 4 Spool Support 5 Wire Drive Assembly 6 Automatic Welding Gun 1 2 6 3 4 5 5 2 Mounting Hole Layout Ref 803 021 B 8 in 203 mm 10 3 4 in...

Страница 19: ...elding power source and weld control and disconnect input power before making connections Use remote voltage sense leads in all applications Suggested size remote voltage sense wire is 12 gauge or hig...

Страница 20: ...er access hole prior to making connections to internal terminal blocks 4 4 Pin Receptacle Connection To Flux Hopper Shielding Gas Valve 5 14 Pin Receptacle Connection To Welding Power Source 6 10 Pin...

Страница 21: ...lock TB2 3 Terminal Block TB1 4 Securing Screw Terminal Block 5 Stripped Lead 6 Typical Lead Being Connected To Terminal Block 7 Access Hole Used For Connections To Terminal Blocks Flux Valve etc Inst...

Страница 22: ...Remote Jog Down When connected to remote common jogs wire down Remote Common Circuit common for remote capabilities 5 7 Terminal Block TB2 Connection Information Terminals Function Information Red 115...

Страница 23: ...minal Block TB2 3 Access Hole Used For Connections To Terminal Blocks Flux Valve etc Install strain relief customer supplied in access hole Strip 1 4 in 6 mm insulation off end of leads Insert four co...

Страница 24: ...g 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 Remote Output Control C C Remote command...

Страница 25: ...ia TB2 Terminal Socket Information Flux Hopper Hookups A Red 115 volts AC to power flux hopper B Black Switched 115 volts AC to power flux hopper C White Circuit common for 115 volts AC for flux hoppe...

Страница 26: ...nse leads are out of the current paths Sense leads detect arc voltage ac curately Best starts arcs and most reliable results BAD Sense lead is affected by weld current Due to voltage drops across work...

Страница 27: ...rops across work piece arc voltage may be low causing need for deviation from standard procedures BAD Current flow from lead affects trail sense Current flow from trail affects lead sense Neither sens...

Страница 28: ...the current paths Both sense leads detect arc volt age accurately No voltage drop between lead and trail sense Best starts arcs and most reliable results Work Clamp Trail Lead Trail Lead 5 13 Remote V...

Страница 29: ...ing a power source selection the operator may press the Program Button to avoid having to wait the five seconds When turning off the controller the selected power source will be retained Next Time Con...

Страница 30: ...asses With Side Shields 3 Welding Helmet With Correct Shade Of Filter See ANSI Z49 1 sb3 1 1 94 1 2 3 6 2 Power Switch And Buttons 803 448 A 1 Power Switch 2 Start Button 3 Stop Button 4 Inch Up Butto...

Страница 31: ...D The upper display push button LED illumi nates to indicate that information displayed can be changed with the Adjust control 4 Volts LED 5 Time LED The LED s below the display illuminate to in dicat...

Страница 32: ...tive The Adjust control can be used to change the setting from AUTO to a run in wire speed setting If a start condi tion is set run in is a percentage of the start wire speed otherwise run in is a per...

Страница 33: ...nce push button flashes and the Start LEDs flash In this condition the unit is in the Start sequence display mode and Start se quence parameters are shown in the dis plays When the Sequence push butto...

Страница 34: ...also turn off the password code feature 2 Power Source Selection The upper display shows PSS The lower display shows ON or OFF Use Adjust control to select ON or OFF 3 Voltage Range Lock Voltage range...

Страница 35: ...B1 will engage when the start but ton is pressed but the weld sequence will not start until the selected time has elapsed 12 Remote Program Select Remote program select is indicated when PSEL is shown...

Страница 36: ...y the gas flow function and CV C mode is not available The Flux button now controls the gas flow Refer to section 6 10 for operating instructions 6 13 Operation Of HDC In GMAW MIG Mode 1 4 Ref 803 449...

Страница 37: ...following table Program Selected RC24 Pin 1 to Pin 2 RC26 Pin 1 to Pin 2 Program 1 Not Connected Not Connected Program 2 Not Connected Connected Program 3 Connected Not Connected Program 4 Connected C...

Страница 38: ...set to zero in any timed se quence except Weld the sequence is skipped Sequence Parameters Volts CV or CV C Amps CV C Wirespeed CV Seconds 1 Preflow 2 Run In 3 Start 4 Weld 5 Crater 6 Burnback 7 Post...

Страница 39: ...14 pin cord Check gas hose and fittings Check gun cable Replace cracked parts 6 Months Blow out or vacuum inside During heavy service clean monthly OR Clean drive rolls 10 2 Circuit Breaker CB1 Turn...

Страница 40: ...amps for the unit to go from run in to weld parameters Have Factory Authorized Service Agent check control board PC1 and replace if necessary No contactor control for welding power source ensure that...

Страница 41: ...m any grounded equipment Turn the unit off for 10 seconds to clear the error message Separate welding cables from control cables Noise is creating an excessive amount of current in the safety ground U...

Страница 42: ...OM 212 296 Page 36 SECTION 11 ELECTRICAL DIAGRAM 238 416 A Figure 11 1 Circuit Diagram...

Страница 43: ...OM 212 296 Page 37 Notes...

Страница 44: ...011 611 Switch Tgl Dpdt 15A 1 9 236 564 Overlay Front Panel CE 1 10 240 509 Circuit Card Assy Switches 1 11 242 318 Circuit Card Assy Display Micro W Program 1 12 221 404 XFMR Control 30Va 24V 24V 18...

Страница 45: ...h 1 236 767 Label CB1 1 236 565 Label Warning Electric Shock Power Still Present 1 236 569 Label Rating Card CSA CE 300438 1 236 226 Label Remote Connections 1 212 591 Cable Motor 10 Ft 10 Pin 1 178 8...

Страница 46: ...auge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERE...

Страница 47: ...s MIG Guns and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Sp...

Страница 48: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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