Miller HDC 1500DX Owner's Manual
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Miller HDC 1500DX Owner's Manual

Submerged arc controller for automatic welding
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HDC 1500DX
OM-212 296Y
2016−06−28
Processes
Submerged (SAW) Welding
Description
Submerged Arc Controller For
Automatic Welding
50, 60 Hz
File: SUBMERGED (SAW)

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Summary of Contents for Miller HDC 1500DX

  • Page 1 OM-212 296Y 2016−06−28 Processes Submerged (SAW) Welding Description Submerged Arc Controller For Automatic Welding HDC 1500DX 50, 60 Hz For product information, File: SUBMERGED (SAW) Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ..............5-3. Typical Connection Diagram With Miller Power Sources .
  • Page 4 TABLE OF CONTENTS 6-12. Operation Of HDC In GMAW (MIG) Mode ..........SECTION 7 −...

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

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

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

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

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

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

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

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

  • Page 12: Proposition Californienne 65 Avertissements

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

  • Page 13: Section 3 − Definitions

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

  • Page 14: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Description This weld control is designed to au- tomatically cycle welding events. This unit can be used with constant voltage, AC or DC welding power sources. Relay contacts that work in conjunction with the weld cycle are available to interface with other equipment (such as fixtures and flux valves).

  • Page 15: Environmental Specifications

    4-4. Environmental Specifications A. IP Rating IP Rating Operating Temperature Range Storage Temperature Range IP21 -4 to 131 °F (-20 to 55°C) 14 to 104 °F (-10 to 40°C) This equipment is designed for indoor use and IP21 2014−06 is not intended to be used or stored outside. B.

  • Page 16: Section 5 − Installation

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

  • Page 17: Typical Connection Diagram With Miller Power Sources

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

  • Page 18: Left Side Panel Connections

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

  • Page 19: Terminal Block Tb1 And Tb2 Connections

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

  • Page 20: Terminal Block Tb1 Connection Information

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

  • Page 21: Connection Of 115 Vac Flux Hopper Without Plug

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

  • Page 22: Remote 10 Receptacle Rc2 Information

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

  • Page 23: Remote 4 Receptacle Rc3 Information

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

  • Page 24: Remote Voltage Sense Leads Placement Guidelines For A Single Arc (Required)

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

  • Page 25: Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs

    5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs Lead WELDING POWER Current flow from lead affects trail SOURCE sense. Current flow from trail affects lead sense. Neither sense lead picks up the correct work voltage, causing starting and welding arc instability. Trail Remote Voltage WELDING...
  • Page 26 5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs (Continued) Lead WELDING Refer to power source owner’s manual for BEST POWER sense lead connection to terminal strip. SOURCE Both sense leads are out of the current paths. Both sense leads detect arc volt- age accurately.

  • Page 27: Power Source Selection Menu

    5-14. Power Source Selection Menu Upper Display Lower Display When the controller is turned on, the Power Source Selec- tion Menu allows the operator to select a power source. First Time Controller Is Turned The controller automatically goes into the Power Source Selection Menu.

  • Page 28: Section 6 − Operation

    SECTION 6 − OPERATION The following is a list of terms and their definitions as they apply to this product. General Terms: Sequence A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow. Weld Program A group of sequences that make up a weld cycle.

  • Page 29: Front Panel Controls

    6-3. Front Panel Controls Section 6-2 Section 6-4 Section 6-5 Section 6-9 Section 6-8 Section 6-6 See Section 6-7 Ref. 236 564-B 6-4. Upper Display (sec) • If the unit is displaying a welding sequence Upper Display Upper Display Push Button LED that can be timed, the welding time display The upper display push button LED illumi- The upper display shows voltage or time.

  • Page 30: Lower Display

    6-5. Lower Display • At any time during welding, the weld se- Lower Display Lower Display Push Button LED quence wire speed can be adjusted and The lower display push button LED illumi- The lower display shows wire speed or am- overrides the preset wire speed display.

  • Page 31: Adjust Control

    6-7. Adjust Control Adjust Control The Adjust control is used to change various sequence parame- ters, and to select various se- quences. Refer to the section for the function in question for informa- tion related to using the Adjust con- trol.

  • Page 32: Auxiliary Menus

    6-10. Auxiliary Menus Program Display Program Push Button Sequence Push Button Upper Display Upper Display Push Button Lower Display Lower Display Push Button Adjust Control Setup Push Button 10 Flux Push Button 11 Lock LED Ref. 236 564-B Auxiliary Menus (Continued) •...

  • Page 33: Operation Of Hdc In Normal Mode

    ”RLAY” in the upper display. display, the resettable number of arc cycles The number of programs is indicated by When the HDC 1500DX is powered off, the is shown in the lower display, wrapping to “NUMB” is shown in the upper display and SB1 and SB2 relay closures are open.

  • Page 34: Operation Of Hdc In Gmaw (Mig) Mode

    6-12. Operation Of HDC In GMAW (MIG) Mode Turn Off welding power source and weld control, and disconnect input power be- fore opening access door. Screws (3) Access Door Remove screws and open access door. Switch (S1) Place switch one in on position. 1 MIG Function Front Display Board 2 No Function...

  • Page 35: Section 7 − Remote Program Select

    If method 2 is used, method 2 will automatically disable method 1. SECTION 8 − MOTOR TYPES For the HDC 1500DX to work properly, the motor used must match the motor selected. The motor is selected in the Auxiliary Menu (see Section 6-10 on Wire Drive Motor Type).

  • Page 36: Section 9 − Setting Sequence Parameters

    SECTION 9 − SETTING SEQUENCE PARAMETERS 9-1. Sequence Parameters In A Program For more information on Se- quence push buttons, see Sec- tion 6-8. If time is set to zero in Weld se- quence, welding continues until stop button is pressed. Parameters Sequence If time is set to zero in any timed se-...

  • Page 37: Section 10 − Maintenance & Troubleshooting

    10-2. Circuit Breaker CB1 Turn welding power source and weld control. Circuit Breaker CB1 CB1 protects the HDC 1500DX inter- nal circuits from overload. If CB1 opens, all operations stop. Correct the problem, and press button to re- set breaker. Ref. 803 449-A...
  • Page 38 Check the push buttons, and replace if necessary (see Section 6-3 and Parts List). (On power up the HDC 1500DX checks the push buttons to see if any are stuck.) Turn the unit off for 10 seconds to clear the error message.
  • Page 39 Trouble Remedy Unit displays GRND EROR. Welding current is present in the safety ground. Isolate welding wire and torch from 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.) Unit displays COM EROR.

  • Page 40: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM 238 416-A Figure 11-1. Circuit Diagram OM-212296 Page 36...

  • Page 41: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 803 627-D Figure 12-1. Control Box Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-1 Control Box Assembly ... . . 214 799 .
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 12-1 Control Box Assembly (Continued) ... . . 117 860 ..Blank, Snap-In Nyl .187 Mtg Hole Black ......
  • Page 43 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 44 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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