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

Miller HDC 1500DX CE Owner's Manual

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HDC 1500DX
OM-212 296S
2009−03
Processes
Submerged (SAW) Welding
Description
Submerged Arc Controller For
Automatic Welding
CE
50, 60 Hz
File: SUBMERGED (SAW)

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  • Page 1 OM-212 296S 2009−03 Processes Submerged (SAW) Welding Description Submerged Arc Controller For Automatic Welding HDC 1500DX 50, 60 Hz File: SUBMERGED (SAW) Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ..............5-3. Typical Connection Diagram With Miller Power Sources .
  • Page 4 TABLE OF CONTENTS SECTION 10 − MAINTENANCE & TROUBLESHOOTING ......... . 10-1.
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

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

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 12 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tel D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 14: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...

  • Page 15: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperes Remote Output Hertz Single Phase Rated Welding Volts Input Alternating Current Current Increase/Decrease Percent Circuit Breaker Wire Feed Speed Of Quantity Protective Earth Postflow Timer Preflux Timer Start Time (Ground) Degree Of Start Stop Primary Voltage...

  • Page 17: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Weld Control Specification Description Type Of Input Power From Welding Single-Phase 115 Volts AC, 10 Amperes, 50/60 Hertz Power Source Welding Power Source Type Constant Voltage (CV), AC Or DC Welding Processes Submerged Arc (SAW) Welding Overall Dimensions Including Knobs, Weld Control —...

  • Page 18: 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 (273 mm) 7 in...

  • Page 19: 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 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28 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 29: 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 30: 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 31: Front Panel Controls

    6-4. Front Panel Controls Section 6-3 Section 6-5 Section 6-6 Section 6-10 Section 6-9 Section 6-7 See Section 6-8 Ref. 236 564-B 6-5. 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 32: Lower Display

    6-6. Lower Display Lower Display Lower Display Push Button LED • At any time during welding, the weld se- 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 33: Adjust Control

    6-8. 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 34: Auxiliary Menus

    6-11. 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 35: Operation Of Hdc In Normal Mode

    Program Display. When paralleling two is shown in the lower display, wrapping to If a reset is not desired, turn Adjust control power sources with a Miller Paralleling Kit, the upper display. The resettable number of until lower display shows”OFF”, and simul- select ”1”...

  • Page 36: Operation Of Hdc In Gmaw (Mig) Mode

    6-13. 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 37: Section 7 − Remote Program Select

    SECTION 7 − REMOTE PROGRAM SELECT There are two methods to remotely change programs. Method 1 In the auxiliary menu, turn remote program select off (see Section 6-11 Remote Program Select). Then connecting Terminal Block TB2 Remote Pro- gram (see Section 5-7 Terminal Block TB2 Connection Information) to Terminal Block TB1 Remote Common (see Section 5-6 Terminal Block TB1 Connection Information) will increment the program.

  • Page 38: 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 6-9. 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 39: Section 10 − Maintenance & Troubleshooting

    SECTION 10 − MAINTENANCE & TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power before maintaining. 3 Months Repair or Clean and Replace replace tighten unreadable cracked weld labels. weld terminals. cable. Replace Check Check gas Check cracked 14-pin hose and parts. cord. fittings.
  • Page 40 10-3. Troubleshooting Table Trouble Remedy Unit is completely inoperative. Check circuit breaker CB1, and reset if necessary (see Section 10-2). Place Power Switch S1 in On position (see Section 6-4). Wire does not feed during jogging. Check 115 volts ac input power and be sure it is energized. Check circuit breaker CB1, and reset if necessary (see Section 10-2).
  • Page 41 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 42: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM 238 416-A Figure 11-1. Circuit Diagram OM-212 296 Page 36...
  • Page 43 Notes OM-212 296 Page 37...

  • Page 44: 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 45 Item Dia. Part Mkgs. Description Quantity Figure 12-1 Control Box Assembly (Continued) ... . . 117 860 ..Blank, Snap-In Nyl .187 Mtg Hole Black ......
  • Page 46 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 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)
  • Page 47 Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...

  • Page 48: Options And Accessories

    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 2009 Miller Electric Mfg. Co. 2009−01...

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