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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

guarantees or warranties expressed or implied.

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.
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 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 delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Fume Extractors
* 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.)

* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries
5. 90 Days — Parts

* 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)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue

®

 Limited Warranty shall not apply to:

1.

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.

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.

 

Summary of Contents for HDC 1500DX CE

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 6: ......

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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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