50, 60 Hz

Processes

Description

OM-212 296DOctober 2004

Submerged (SAW) Welding

Submerged Arc Controller For Automatic Welding

HDC 1500DX

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit 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 superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat 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 yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do− every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . . 2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS (CE Models Only) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Warning Label Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Manufacturer’s Rating Label For CE Products Only 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Symbols And Definitions* 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Weld Control 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Description 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Typical Equipment Location 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Mounting Hole Layout 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Rating Label For Non-CE Products Only 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Connection Diagram With Miller Power Sources 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Connection Diagram With Non-Miller Power Sources 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Left Side Panel Connections 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Terminal Block TB1 And TB2 Connections 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Terminal Block TB1 Connection Information 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Terminal Block TB2 Connection Information 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Typical Connection Of A Flux Hopper With Automatic 115 VAC To An HDC 1500DX 18 . . . . . . . . . . . . . 5-11. Remote 10 Receptacle RC2 Information 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Remote 14 Receptacle RC1 Information 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Safety Equipment 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Power Switch And Buttons 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Program Push Buttons 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Front Panel Controls 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Upper Display 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Lower Display 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Setup Push Button 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8. Adjust Control 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Sequence Push Button 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10. Flux Push Button 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11. Auxiliary Menus 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − Motor T ypes 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − Setting Sequence Parameters 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Sequence Parameters In A Program 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Calibrating The HDC 1500DX 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Circuit Breaker CB1 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 10 − ELECTRICAL DIAGRAM 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − PARTS LIST 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIESWARRANTY

dec_con1_11/02

Declaration of Conformity forEuropean Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.Manufacturer’s Address: 1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product: HDC 1500DXconforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic Compatibility (EMC) Directive: 89/336/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Standards

Arc Welding Equipment Part I: Welding Power Sources: IEC 974-1(April 1995 − Draft Revision)

Arc Welding Equipment: Wirefeed Systems: IEC 974-4(May 1995 − Draft Revision)

Degrees of Protection Provided By Enclosures (IP Code): IEC 529:1989

Insulation Coordination For Equipment With Low-Voltage Systems:Part I: Principles, Requirements and Tests: IEC 664-1: 1992

Electromagnetic Compatibility, (EMC): EN 50199

European Contact: Mr. Danilo Fedolfi, Managing DirectorITW WELDING PRODUCTS ITALY S.r.l.Via Privata Iseo 6/E20098 San GiulianoMilanese, Italy

Telephone: 39(02)98290-1Fax: 39(02)98290-203

OM-212 296 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

� Marks a special safety message.

� Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

� The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, a nd follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

� Only qualified persons should install, operate, maintain, andrepair this unit.

� During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

� Do not touch live electrical parts.

� Wear dry, hole-free insulating gloves and body protection.

� Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

� Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

� Use AC output ONLY if required for the welding process.

� If AC output is required, use remote output control if present onunit.

� Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

� Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.

� Always verify the supply ground − check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

� When making input connections, attach proper grounding conduc-tor first − double-check connections.

� Frequently inspect input power cord for damage or bare wiring −replace cord immediately if damaged − bare wiring can kill.

� Turn off all equipment when not in use.

� Do not use worn, damaged, undersized, or poorly spliced cables.

� Do not drape cables over your body.

� If earth grounding of the workpiece is required, ground it directlywith a separate cable.

� Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

� Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

� Wear a safety harness if working above floor level.

� Keep all panels and covers securely in place.

� Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.

� Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

� Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.� Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

� Keep your head out of the fumes. Do not breathe the fumes.

� If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.

� If ventilation is poor, use an approved air-supplied respirator.

� Read the Material Safety Data Sheets (MSDSs) and themanufacturer’s instructions for metals, consumables, coatings,cleaners, and degreasers.

� Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

� Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

� Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.

OM-212 296 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

� Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

� Wear approved safety glasses with side shields under yourhelmet.

� Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

� Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

� Protect yourself and others from flying sparks and hot metal.

� Do not weld where flying sparks can strike flammable material.

� Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

� Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

� Watch for fire, and keep a fire extinguisher nearby.

� Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

� Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

� Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.

� Do not use welder to thaw frozen pipes.

� Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

� Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

� Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

FLYING METAL can injure eyes.

� Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

� Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

� Shut off shielding gas supply when not in use.� Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

� Do not touch hot parts bare handed.� Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

� Pacemaker wearers keep away.� Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

� Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

� Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

� Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

� Keep cylinders away from any welding or other electrical circuits.

� Never drape a welding torch over a gas cylinder.

� Never allow a welding electrode to touch any cylinder.

� Never weld on a pressurized cylinder − explosion will result.

� Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

� Turn face away from valve outlet when opening cylinder valve.

� Keep protective cap in place over valve except when cylinder is inuse or connected for use.

� Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in SafetyStandards.

OM-212 296 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

� Do not install or place unit on, over, or nearcombustible surfaces.

� Do not install unit near flammables.

� Do not overload building wiring − be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

� Use equipment of adequate capacity to lift andsupport unit.

� If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before

starting to weld again.� Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

� Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

� Keep away from moving parts.� Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

� Do not press gun trigger until instructed to doso.

� Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

� Keep away from moving parts such as fans.� Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

� Have only qualified persons familiar withelectronic equipment perform this installation.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

� If notified by the FCC about interference, stop using theequipment at once.

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

� Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

� Be sure all equipment in the welding area iselectromagnetically compatible.

� To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

� Locate welding operation 100 meters from any sensitive elec-tronic equipment.

� Be sure this welding machine is installed and groundedaccording to this manual.

� If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

� Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

� Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines:� Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines:� Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

OM-212 296 Page 4

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).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269−9101 (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, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, 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).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Offices−−phone for Region 5, Chicago, is312−353−2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: “The body of evidence, in thecommittee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.”However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

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 opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.

OM-212 296 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANTUTILISATION

som_fre 8/03

2-1. Signification des symboles

Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives.

� 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 vigi-lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, auxPIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporteraux symboles et aux directives ci-dessous afin de connaître les me-sures à prendre pour éviter tout danger.

2-2. Dangers relatifs au soudage à l’arc

� Les symboles ci-après sont utilisés tout au long du présentmanuel pour attirer l’attention sur les dangers potentiels et lesidentifier. Lorsqu’on voit un symbole, faire preuve de vigilance etsuivre les directives mentionnées afin d’éviter tout danger. Lesconsignes de sécurité énoncées ci-après ne font que résumer lecontenu des normes de sécurité mentionnées à la section 2-4.Lire et respecter toutes ces normes.

� L’installation, l’utilisation, l’entretien et les réparations ne doi-vent être confiés qu’à des personnes qualifiées.

� Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUESpeuvent être mortelles.Un simple contact avec des pièces sous tension peutcauser une électrocution ou des blessures graves.L’électrode et le circuit de soudage sont sous tensiondès 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, lelogement des galets d’entraînement et les pièces métalliques en contactavec le fil de soudage sont sous tension. Tout matériel mal installé ou malmis à la terre présente un danger.

� Ne jamais toucher aux pièces électriques sous tension.� Porter des gants et des vêtements de protection secs et exempts de

trous.� S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empêcher tout contactphysique avec la pièce ou la terre.

� Ne pas se servir d’une source de courant alternatif dans les zones humi-des, les endroits confinés ou là où on risque de tomber.

� Ne se servir d’une source de courant alternatif QUE si le procédé de souda-ge l’exige.

� Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-vir de la fonction de télécommande si l’appareil en est équipé.

� Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueterl’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-mes de sécurité).

� Installer et mettre à la terre correctement l’appareil conformément àson manuel d’utilisation et aux codes nationaux, provinciaux etmunicipaux.

� Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu-rer que le fil de terre du cordon d’alimentation est bien raccordé à laborne de terre du sectionneur ou que la fiche du cordon est raccordéeà une prise correctement mise à la terre.

� Pour exécuter les branchements d’entrée, fixer d’abord le conducteurde mise à la terre adéquat et contre−vérifier les connexions.

� Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’estni endommagé ni dénudé ; le remplacer immédiatement s’il est en-dommagé − tout câble dénudé peut causer une électrocution.

� Mettre l’appareil hors tension quand on ne l’utilise pas.� Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou

mal épissés.� Ne pas s’enrouler les câbles autour du corps.� Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.� Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode d’une autre machine.

� N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−champ les pièces endommagées. Entretenir l’appareil conformémentau présent manuel.

� Porter un harnais de sécurité quand on travaille en hauteur.

� Maintenir solidement en place tous les panneaux et capots.

� Fixer le câble de retour de façon à obtenir un bon contact métal surmétal avec la pièce à souder ou la table de travail, le plus près possiblede la soudure.

� Ne pas connecter plus d’une électrode ou plus d’un câble de masse à unmême terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANTdans les convertisseurs après la suppression del’alimentation électrique.� Arrêter les convertisseurs, débrancher le courant électrique et dé-

charger les condensateurs d’alimentation selon les instructionsénoncées à la section Entretien avant de toucher les pièces.

Le soudage génère des fumées et des gaz dontl’inhalation peut être dangereuse pour la santé.

LES FUMÉES ET LES GAZ peuventêtre dangereux.

� Se tenir à distance des fumées et ne pas les inhaler.

� À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration auniveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

� Si la ventilation est insuffisante, utiliser un respirateur à adductiond’air agréé.

� Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-tions du fabricant concernant les métaux, les consommables, lesrevêtements, les nettoyants et les dégraisseurs.

� Ne travailler dans un espace clos que s’il est bien ventilé ou porter unrespirateur à adduction d’air. Demander toujours à un surveillant dû-ment formé de se tenir à proximité. Des fumées et des gaz de soudagepeuvent se substituer à l’air, abaisser la teneur en oxygène et causerdes lésions ou des accidents mortels. S’assurer que l’air est respira-ble.

� Ne pas souder à proximité d’opérations de dégraissage, de nettoyageou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir enprésence de vapeurs et former des gaz hautement toxiques et irri-tants.

� Ne pas souder de métaux munis d’un revêtement, tels que la tôled’acier galvanisée, plombée ou cadmiée, à moins que le revêtementn’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti-lé, et si nécessaire, porter un respirateur à adduction d’air. Lesrevêtements et tous les métaux renfermant ces éléments peuvent dé-gager des fumées toxiques lorsqu’on les soude.

OM-212 296 Page 6

Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brûlures oculaires et cutanées.Des étincelles sont projetées pendant le soudage.

LES RAYONS DE L’ARC peuvent cau-ser des brûlures oculaires et cuta-nées.

� Porter un masque de soudage muni d’un filtre de la nuance adéquatepour se protéger le visage et les yeux pendant le soudage ou pour re-garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).

� Porter des lunettes de sécurité à écrans latéraux sous le masque.� Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat

éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarderl’arc.

� Porter des vêtements de protection en matière durable et ignifuge(cuir ou laine) et des chaussures de sécurité.

Le soudage effectué sur des récipients fermés tels quedes réservoirs, des fûts ou des conduites peut causerleur éclatement. Des étincelles peuvent être projetéesde l’arc de soudure. La projection d’étincelles, les

pièces chaudes et les équipements chauds peuvent causer desincendies et des brûlures. Le contact accidentel de l’électrode avec toutobjet métallique peut causer des étincelles, une explosion, un surchauf-fement ou un incendie. Avant de commencer le soudage, vérifier ets’assurer que l’endroit ne présente pas de danger.

LE SOUDAGE peut causer un incen-die ou une explosion.

� Se protéger et protéger les tiers de la projection d’étincelles et de mé-tal chaud.

� Ne pas souder à un endroit où des étincelles peuvent tomber sur dessubstances inflammables.

� Placer toutes les substances inflammables à une distance de 10,7 mde l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse-ment avec des protections agréées.

� Des étincelles et des matières en fusion peuvent facilement passermême par des fissures et des ouvertures de petites dimensions.

� Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-mité.

� Le soudage effectué sur un plafond, un plancher, une paroi ou unecloison peut déclencher un incendie de l’autre côté.

� Ne pas souder des récipients fermés tels que des réservoirs, des fûtsou des conduites, à moins qu’ils n’aient été préparés conformément àl’AWS F4.1 (voir les normes de sécurité).

� Brancher le câble sur la pièce le plus près possible de la zone de sou-dage pour éviter que le courant ne circule sur une longue distance, pardes chemins inconnus, et ne cause des risques d’électrocution et d’in-cendie.

� Ne pas utiliser le poste de soudage pour dégeler des conduites ge-lées.

� En cas de non utilisation, enlever la baguette d’électrode du porte−électrode ou couper le fil au raz du tube−contact.

� Porter des vêtements de protection exempts d’huile tels que desgants en cuir, une chemise en tissu épais, des pantalons sans revers,des chaussures montantes et un masque.

� Avant de souder, retirer tout produit combustible de ses poches, telqu’un briquet au butane ou des allumettes.

LES PARTICULES PROJETÉES peu-vent blesser les yeux.

� Le soudage, le burinage, le passage de la pièce àla brosse métallique et le meulage provoquentl’émission d’étincelles et de particules métalli-

ques. Pendant leur refroidissement, les soudures risquent de projeter dulaitier.� Porter des lunettes de sécurité à écrans latéraux agréés, même sous le

masque de soudage.

LES ACCUMULATIONS DE GAZ peu-vent causer des blessures ou mêmela mort.

� Couper l’alimentation en gaz protecteur en cas denon utilisation.

� Veiller toujours à bien ventiler les espaces confinés ou porter un respira-teur à adduction d’air agréé.

LES PIÈCES CHAUDES peuvent cau-ser des brûlures graves.

� Ne pas toucher les pièces chaudes à main nue.� Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuventperturber le fonctionnement des stimu-lateurs cardiaques.

� Les personnes qui portent un stimulateur cardiaquedoivent se tenir à distance.

� Ils doivent consulter leur médecin avant de s’appro-cher d’un lieu où on exécute des opérations de sou-dage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit de certains processus et équipements peutaffecter l’ouïe.

� Porter des protecteurs d’oreille agréés si le niveausonore est trop élevé.

Les bouteilles de gaz protecteur contiennent du gazsous haute pression. Toute bouteille endommagéepeut exploser. Comme les bouteilles de gaz fontnormalement partie du procédé de soudage, les

manipuler avec précaution.

Les BOUTEILLES endommagéespeuvent exploser.

� Protéger les bouteilles de gaz comprimé de la chaleur excessive, deschocs mécaniques, du laitier, des flammes nues, des étincelles et desarcs.

� Placer les bouteilles debout en les fixant dans un support stationnaireou dans un porte−bouteilles pour les empêcher de tomber ou de serenverser.

� Tenir les bouteilles éloignées des circuits de soudage ou autres cir-cuits électriques.

� Ne jamais poser une torche de soudage sur une bouteille de gaz.� Ne jamais mettre une électrode de soudage en contact avec une bou-

teille de gaz.� Ne jamais souder une bouteille contenant du gaz sous pression − elle

risquerait d’exploser.� N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords adéquats pour l’application envisagée ; les maintenir en bonétat, ainsi que les pièces connexes.

� Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.� Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-

tion ou de branchement de la bouteille� Lire et suivre les instructions concernant les bouteilles de gaz compri-

mé, les équipements associés et les publications P−1 de la CGA,mentionnées dans les normes de sécurité.

OM-212 296 Page 7

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien del’appareil.

Risque D’INCENDIE OU D’EXPLO-SION

� Ne pas placer l’appareil sur une surface inflam-mable, ni au−dessus ou à proximité d’elle.

� Ne pas installer l’appareil à proximité de produits inflammables.� Ne pas surcharger l’installation électrique − s’assurer que l’alimen-

tation est correctement dimensionnée et protégée avant de mettrel’appareil en service.

LA CHUTE DE L’APPAREIL peutblesser.

� N’utiliser que l’anneau de levage pour lever l’ap-pareil. NE PAS utiliser le chariot, les bouteilles degaz ou tout autre accessoire.

� Utiliser un engin de capacité adéquate pour leverl’appareil.

� Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer queles fourches sont suffisamment longues pour dépasser du côté op-posé de l’appareil.

L’EMPLOI EXCESSIF peut FAIRESURCHAUFFER L’ÉQUIPEMENT.

� Prévoir une période de refroidissement ; respec-ter le cycle opératoire nominal.

� Réduire le courant ou le cycle opératoire avant dereprendre le soudage.

� Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

LES CHARGES ÉLECTROSTATI-QUES peuvent endommager les cir-cuits imprimés.

� Mettre un bracelet antistatique AVANT de mani-puler des cartes ou des pièces.

� Utiliser des pochettes et des boîtes antistatiquespour stocker, déplacer ou expédier des cartes decircuits imprimés.

LES PIÈCES MOBILES peuvent cau-ser des blessures.

� Se tenir à l’écart des pièces mobiles.� Se tenir à l’écart des points de coincement tels

que les dévidoirs.

LES FILS DE SOUDAGE peuvent cau-ser des blessures.

� Ne pas appuyer sur la gâchette avant d’en avoirreçu l’instruction.

� Ne pas diriger le pistolet vers soi, vers d’autrespersonnes ou vers toute pièce mécanique en en-gageant le fil de soudage.

LES ORGANES MOBILES peuventcauser des blessures.

� Se tenir à l’écart des organes mobiles comme lesventilateurs.

� Maintenir fermés et bien fixés les portes,panneaux, recouvrements et dispositifs deprotection.

LE RAYONNEMENT HAUTE FRÉ-QUENCE (H. F.) risque de causer desinterférences.

� Le rayonnement haute fréquence peut causerdes interférences avec les équipements de radio-navigation et de communication, les services desécurité et les ordinateurs.

� Ne demander qu’à des personnes qualifiées familiarisées avec leséquipements électroniques de faire fonctionner l’installation.

� L’utilisateur est tenu de faire corriger rapidement par un électricienqualifié les interférences causées par l’installation.

� Si la Federal Communications Commission signale des interféren-ces, arrêter immédiatement l’appareil.

� Faire régulièrement contrôler et entretenir l’installation.� Maintenir soigneusement fermés les panneaux et les portes des sour-

ces de haute fréquence, maintenir le jeu d’éclatement au réglageadéquat et utiliser une terre et un blindage pour réduire les interféren-ces éventuelles.

LE SOUDAGE À L’ARC peut causerdes interférences.

� L’énergie électromagnétique peut causer desinterférences avec l’équipement électroniquesensible tel que les ordinateurs et l’équipementcommandé par ordinateur tel que les robots.

� Veiller à ce que tout l’équipement de la zone de soudage soit compati-ble au point de vue électromagnétique.

� Pour réduire la possibilité d’interférence, maintenir les câbles de sou-dage aussi courts que possible, les grouper, et les poser aussi basque possible (par ex. : à terre).

� Veiller à souder à une distance de 100 mètres de tout équipementélectronique sensible.

� Veiller à ce que le poste de soudage soit posé et mis à la terre confor-mément au présent manuel.

� En cas d’interférences après exécution des directives précédentes, ilincombe à l’utilisateur de prendre des mesures supplémentaires tel-les que le déplacement du poste, l’utilisation de câbles blindés,l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNÉTIQUES peuventaffecter les stimulateurs cardiaques.

� Porteurs de stimulateur cardiaque, restez à dis-tance.

� Les porteurs d’un stimulateur cardiaque doiventd’abord consulter leur médecin avant de s’appro-cher des opérations de soudage à l’arc, de gou-geage ou de soudage par points.

OM-212 296 Page 8

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).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, norme American Welding Society AWSF4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org etwww.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 Ca-nadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna-tional.org).

Practice For Occupational And Educational Eye And Face Protection,norme ANSI Z87.1, de l’American National Standards Institute, 11 West42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, norme NFPA 51B, de la National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a10 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 magnéti-ques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs élec-tromagnétiques. Les effets potentiels de tels champs restentpréoccupants. Cependant, après avoir examiné plus de 500 études quiont été faites pendant une période de recherche de 17 ans, un comitéde spécialistes du National Research Council a conclu : « L’accumula-tion de preuves n’a pas démontré que l’exposition aux champsmagnétiques et aux champs électriques à haute fréquence constitue unrisque pour la santé humaine ». Toutefois, les études et l’examen despreuves se poursuivent. En attendant les conclusions finales de la re-cherche, il serait souhaitable de réduire l’exposition aux champsélectromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, res-pecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec duruban 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 toutconsulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-mandé de respecter les consignes ci-dessus.

OM-212 296 Page 9

SECTION 3 − DEFINITIONS (CE Models Only)

3-1. Warning Label Definitions

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from wiring cankill.

3 Disconnect input plug orpower before working onmachine.

4 Become trained and read theinstructions before working onthe machine or welding.

1

32 4

3-2. Manufacturer’s Rating Label For CE Products Only

ST-178 794-A

S/N:

HzIP

V X %MILLER ELECTRIC MFG. CO., APPLETON, WI USA

VU1=AI1=

1

U=2 I= A2

115 50/602X

1500 100100

4

� When using a RAD-400 (Millerpart number 195265) runningat maximum speed and fullyloaded, the HDC 1500DXdraws approximately 4 amps.

−

OM-212 296 Page 10

3-3. Symbols And Definitions*

A Amperes Remote Output Hz Hertz

V Volts InputSingle Phase

AlternatingCurrent

I2Rated Welding

Current

Percent Circuit BreakerIncrease/Decrease

Of Quantity Wire Feed Speed

Protective Earth(Ground) Postflow Timer Preflux Timer Start Time

Start Stop U1Primary Voltage IP Degree Of

Protection

X Duty Cycle I1

Rated Supply

Current241a Primary

current

Line Connection U2Conventional Load

Voltage

On OffWire Feed Inch

Down Wire Feed In Up

Crater Time Program Flux

*Some of these symbols appear on CE models only.

SECTION 4 − SPECIFICATIONS

4-1. Weld Control

Specification Description

Type Of Input Power From WeldingPower Source

Single-Phase 115 Volts AC, 10 Amperes, 50/60 Hertz

Welding Power Source Type 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 100 Volts0 To 1500 Amperes

OM-212 296 Page 11

4-2. Description

This weld control is designed to au-tomatically cycle welding events.This unit can be used with constantvoltage, AC or DC welding powersources. Relay contacts that workin conjunction with the weld cycleare available to interface with otherequipment (such as fixtures andflux valves). See Section 5-7 and5-9 for connection information onTB2.

For information on the wire drive as-sembly, see Owner’s Manual sup-plied with the assembly.

803 448-A

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

OM-212 296 Page 12

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)

5-3. Rating Label For Non-CE Products Only

165 746-B

1001500

115

50/60

100

4

� When using a RAD-400 (Millerpart number 195265) runningat maximum speed and fullyloaded, the HDC 1500DXdraws approximately 4 amps.

OM-212 296 Page 13

5-4. Connection Diagram With Miller Power Sources

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.Note

VoltageSensingCords

10-Pin MotorControl Cord

14-Pin WeldingPower SourceControl Cord

Flux ValveCord

Welding Cables

(SAW)

(Optional)

� Turn Off welding powersource and weld controland disconnect inputpower before makingconnections.

This unit is supplied with 10-pinand 14-pin cords. Select theproper cord and make each ofthe connections shown.

OM-212 296 Page 14

5-5. Connection Diagram With Non-Miller Power Sources

Customer must supply the following: power source, Miller shunt control, power source controlcable, wire drive assembly and drive rolls, gun, welding wire, weld cables, and flux system forthe desired application.

Note

VoltageSensingCords

10-Pin MotorControl Cord

Welding PowerSource Control

Cord

Flux ValveCord

Welding Cables

� Turn Off welding powersource and weld controland disconnect inputpower before making con-nections.

� For non-MILLER powersources, terminal block TB1is required for hookup (SeeSections 5-7 and 5-8).

A voltage sense lead is requiredwhen using a non−MILLER pow-er source. To connect a voltagesense lead, route a two conduc-tor lead through user accesshole and connect to terminals ofTB2 (see Section 5-7). Connectother end of voltage sensing leadto the workpiece, and to thetorch.

(SAW)

SHUNTCONTROL

OM-212 296 Page 15

A J

BK I

C L N H

D M G

E F

1 Receptacle

2 Keyway

3 Access Holes - For CustomerUse: Connections To TerminalBlocks, Flux Valve, etc.

� Turn Off welding powersource and weld control anddisconnect input power be-fore o pening access door.

� Install strain relief (customersupplied) in access hole.

Route incoming cables throughuser access hole prior to makingconnections to internal terminalblocks.

4 14-Pin Receptacle:Connection To Welding PowerSource.

5 10-Pin Receptacle:Connection to Wire DriveMotor

To connect matching interconnect-ing cord to one of the abovereceptacles, align keyway, insertplug, and tighten threaded collar.Connect remaining end of cord tomatching receptacle on applicableequipment.

5-6. Left Side Panel Connections

4

1 2

Ref. 803 022-B

Example Receptacle

5

3

OM-212 296 Page 16

5-7. Terminal Block TB1 And TB2 Connections

Ref. 803 450-B

� Turn Off welding powersource and weld control anddisconnect input power be-fore o pening access door.

1 Access Door

Remove securing screw and openaccess door.

2 Terminal Block TB2

3 Terminal Block TB1

4 Securing Screw - TerminalBlock

5 Stripped Lead

6 Typical Lead BeingConnected To Terminal Block

7 Access Holes - Used ForConnections To TerminalBlocks, Flux Valve, etc.

� Install strain relief (customersupplied) in access hole.

Strip 1/4 in (6 mm) insulation off endof lead, insert end into proper loca-tion on TB1 and TB2. Tighten appli-cable securing screw.

Close and secure access door.

Tools Needed:1

1/4 in(6 mm)

6

5

2

3

4

7

OM-212 296 Page 17

5-8. Terminal Block TB1 Connection Information

Terminal/Number Receptacle Location Function Information

A - 2 A on 14-Pin A normally open set of relay contacts connect terminal A to terminal B whenStart is pressed and pre-flux timer times out (contacts are rated 10 amperes, 125

B - 4 B on 14-PinStart is pressed and pre-flux timer times out (contacts are rated 10 amperes, 125volts 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 weldingpower 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 1500DX.

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 Function Information

Red 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 1500DX Startbutton is pressed and preflux has timed out. Contacts open again when HDC 1500DX 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 wantthe side beam to start moving only after an arc has been established. Contacts open again when HDC 1500DXStop button is pressed.

Remote Start When connected to remote common, starts HDC 1500DX.

Remote Jog Up When connected to remote common, jogs wire up.

Remote Program When connected to remote common, increments the program.

Remote Sense Sense lead inputs.

* NOTE: All contacts are rated 10 amperes, 125 volts AC.

OM-212 296 Page 18

5-10. Typical Connection Of A Flux Hopper With Automatic 115 VAC To An HDC 1500DX

Ref. 803 629-A

� Turn Off welding powersource and weld control anddisconnect input power be-fore opening acc ess door.

1 Access Door

Remove securing screw and openaccess door.

2 Terminal Block TB2

3 Access Holes - Used ForConnections To TerminalBlocks, Flux Valve, etc.

� Install strain relief (customersupplied) in access hole.

Strip 1/4 in (6 mm) insulation off endof leads. Insert four-conductorcables from flux system through ac-cess hole, and make connectionsas shown.

Close and secure access door.

Tools Needed:

Four-Conductor CableFrom Flux System

2

Green Lead

White Lead

Black Lead

Red Lead

Four-Conductor CableFrom Flux System

1

3

OM-212 296 Page 19

5-11. Remote 10 Receptacle RC2 Information

REMOTE 10 Socket 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.

Wirefeed Drive E Chassis common.

Wirefeed Drive Motor Hookups F Tachometer feedback; 0 to +12 volts DC.Motor Hookups

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

SocketUser Accessible

Via TB1

Terminal #Socket Information

Contactor Control

A A24 volts AC or 115 volts AC from welding power source (presentwhenever power source is On).

Contactor ControlB B

Normally open set of relay contacts connect A to B when Start ispressed and preflux timer has timed out.

C C Remote command reference from power source; +10 volts DC.

Remote Output Control D D Remote circuit common.

E E Output command signal to power source; 0 to +10 volts DC.

Amperage/Voltage Feedback

F FCurrent feedback input from power source; +1 volt DC per 100 am-peres.

Amperage/Voltage Feedback

H HVoltage feedback input from power source; +1 volt DC per 10 arcvolts.

G G Circuit common for 24 and 115 volts AC circuits.

Electrical Input PowerI I

115 volts AC from welding power source (present whenever weldingpower source is on). 115 volts AC is present on terminal block TB1whenever welding power source is on.

GND K K Chassis common.

14 Pin Interconnecting Cable

Ref. 178 836

OM-212 296 Page 20

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.

6-1. Safety Equipment

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With SideShields

3 Welding Helmet With CorrectShade Of Filter (See ANSIZ49.1)

sb3.1 1/94

1 23

6-2. Power Switch And Buttons

803 448-A

1 Power Switch

2 Start Button

3 Stop Button

4 Inch Up Button

5 Inch Down Button

2

3

15

4

6-3. Program Push Buttons

1 Program Display

The number of the active programis displayed.

2 Program Push Button

Press button to activate programselected feature. To change theprogram number, press the Pro-gram push button, or rotate the Ad-just control.

3 Program Push Button LED

The LED lights to indicate the Pro-gram push button is active.

Non-CE Models CE Models

Program

3

2

13

2

1

OM-212 296 Page 21

6-4. Front Panel Controls

212 483-A

212 289-A

S E T U P

V t

A

SeeSection 6-3

SeeSection 6-9

SeeSection 6-5

SeeSection 6-6

SeeSection 6-10

SeeSection 6-7

See Section 6-8

Nameplate For Non-CE Models

Nameplate For CE Models

See

See

See

See

Section 6-5

Section 6-6

Section 6-10

Section 6-7

SeeSection 6-3

SeeSection 6-9

See Section 6-8

Program Volts Time (sec)

Wire Speed Amps

StartCrater

Pre-Postflow

Sequence Adjust Setup

OM-212 296 Page 22

6-5. Upper Display

1 Upper Display

The upper display shows voltage or time. Theunit displays both preset and actual arc volt-age. When the unit is in a welding state, actu-al arc voltage is displayed. The upper displayshows welding sequence time when the TimeLED is illuminated.

2 Upper Display Push Button

Press and hold button to adjust or displayweld time. Release button to display voltage.

3 Upper Display Push Button LED

The upper display push button LED illumi-nates to indicate that information displayedcan be changed with the Adjust control.

4 Volts LED

5 Time LED

The LED’s below the display illuminate to in-dicate which value is being shown.

At any time while welding, the unit permits theadjustment of the weld sequence voltage.

• If the unit is displaying a welding sequencethat can be timed, the welding time displaymode is entered by pressing the upper dis-play push button repeatedly until weldingtime is the active parameter in the upperdisplay. At idle, the upper display togglesbetween showing weld voltage or weld timewith subsequence presses of the upperdisplay push button.

• The unit defaults to displaying welding volt-age when a welding sequence displaymode is first entered.

V t

Non-CE Models CE Models

1

4

3

2

55

1

4

3

2

Volts Time (sec)

6-6. Lower Display

1 Lower Display

The lower display shows wire speed or am-perage.

2 Lower Display Push Button

Press button to choose between wire speedor amperage functions.

3 Lower Display Push Button LEDThe lower display push button LED illumi-nates to indicate that information displayedcan be changed with the Adjust control.4 Wire Speed LED5 Amps LEDThe LED’s below the display illuminate to in-dicate which value is being shown.

• At any time during welding, the weld se-quence wire speed can be adjusted andoverrides the preset wire speed display. Inother words, if the Adjust control is acti-vated while welding, the unit displays andpermits adjustment of the weld sequencewire feed speed regardless of the activewelding sequence.

A

2

31

4

5 5

Non-CE Models CE Models

1

4

2

3

Wire Speed Amps

OM-212 296 Page 23

6-7. Setup Push Button

1 Setup Push Button

2 Setup Push Button LED

JOG

The jog speed selection, indicated by “JOG”in the upper display, can be changed by turn-ing the Adjust control. The jog wire feed speedsetting is the same for all programs. The jogwire feed speed may also be adjusted whilethe INCH UP or INCH DOWN buttons arepressed.

Wire Touch Sense

Wire touch sense indicated by “TUCH” in theupper display is set to “OFF” by default. UseAdjust control or lower display push button to-turn wire touch sense “ON”. With wire touchsense “ON”, if the welding wire comes in con-tact with the workpiece while jogging wire,“WIRE” is shown in the upper display and“TUCH” is shown in the lower display. The JogDown button is then disabled and when re-leased, the welding wire will retract for at afixed wirespeed for the selected time (seeSection 6-11).

MODE

Welding mode indicated by “MODE” in the up-per display is set to “CV” for constant voltage,or “CV+C” for constant voltage plus current.This setting is program specific.

Run-In

The run-in wire speed selection, indicated by“RUNI” in the upper display, is set to automat-ic , off, or manual run-in wire speed. The lowerdisplay shows “AUTO” to indicate that auto-matic run-in is active. The Adjust control canbe used to change the setting from “AUTO”,to a run-in wire speed setting. The active pro-gram is displayed in the Program display. Theactive program can be changed by pressingthe Program push button, and then selectingthe desired program with the Adjust control.

Run-in settings are program specific. For ex-ample, program 1 can be set to 50 IPM run-in,and program 2 can remain on the Automaticsetting.

BURNBACK

Burnback time and voltage are specifiedwhen the display indicates “BURN” in the low-er display, and voltage and time in the upperdisplay. The Adjust control is used to set thedesired burnback time or voltage.

Flux Valve Control

Flux valve control, indicated by “FLUX” in theupper display, is set to “AUTO” for automaticcontrol, or “MAN” for manual control. Settingthe Flux valve control to “AUTO” closes theflux valve relay when the Start button ispressed, and opens the flux valve relay whenthe last sequence is finished. The flux valvecontrol can be overridden by using the fluxbutton. Setting the flux valve control to “MAN”requires the user to close and open the fluxvalve relay with the flux button.

Wire Feed Speed Setting

Wire feed speed setting, indicated by “WFS”in the upper display, can be set to “IPM” inch-es-per-minute or “MPM” meters-per-minute.This setting is independent of the program se-lected.

Non-CE Models CE Models

Setup

S E T U P

11

2 2

6-8. Adjust Control

1 Adjust Control

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

1

Non-CE Models CE Models

Adjust

1

OM-212 296 Page 24

6-9. Sequence Push Button

1 Sequence Push Button

2 Sequence Push Button LED

3 Welding Sequence LED’s

3

Non-CE Models CE Models

S tar t

C ra ter

Pre−P os t flo w

Sequence

3

2

1

2

1

� For more information on Setting Se-quence Parameters See Section 8-1.

• The Sequence push button allows theselection of welding sequences. Five weld-ing sequences are available. The defaultsequence is the Weld sequence. The Weldsequence is active upon power up. Threewelding sequence LEDs are located abovethe Sequence push button: Start, Crater,and Preflow/Postflow. The applicable LEDilluminates to indicate the active welding se-quence.

Welding sequences other than weld mustbe set prior to initiating the arc. When theunit enters a welding state, all sequence dis-play modes are terminated and the weld dis-play mode is activated.

If zero time is programmed for a timed se-quence except for Weld, that sequence willbe skipped.

• In the Weld sequence display mode, the Se-quence push button LED is off. When theSequence push button is pressed, the Se-quence push button flashes and the StartLEDs flash. In this condition, the unit is in theStart sequence display mode, and Start se-quence parameters are shown in the dis-plays.

• When the Sequence push button pressed asecond time, the Crater sequence LEDflashes; the Sequence LED also remainsflashing. In this condition, the unit is in theCrater sequence display mode, and theCrater sequence parameters are shown inthe displays.

• When the Sequence push button is presseda third time, the Preflow/Postflow sequenceLED flashes. The Sequence push buttonLED remains flashing. In the Preflow dis-play mode, the upper display shows the pre-flow time, and PRE is shown in the lowerdisplay. To change the preflow time, pressthe upper display and turn the Adjust con-trol.

To select between preflow (PRE) and post-flow (POST), press the lower display buttonand turn the Adjust control. When POST isselected, the upper display is used to speci-fy postflow time.

• When the Sequence button is pressed afourth time, the unit returns to the Weldingsequence display mode.

6-10. Flux Push Button

1 Flux Push Button

2 Flux Push Button LED

Pressing the Flux push buttontoggles the flux valve control openand closed. When the Flux pushbutton LED is lit, the flux valve con-trol is open.

When the flux valve control is set to“AUTO” (see Section 6-7), the fluxvalve opens when the Start buttonis pressed, and closes when thelast sequence is finished.

1

Non-CE Models CE Models

Setup

1

2 2

OM-212 296 Page 25

6-11. Auxiliary Menus

212 289-A / 212 483-A

1 Program Display

2 Program Push Button

3 Sequence Push Button

4 Upper Display

5 Upper Display Push Button

6 Lower Display7 Lower Display Push Button

8 Adjust Control

9 Setup Push Button

10 Flux Push Button

1

Non-CE Models

CE Models

Program

S tar t

C ra ter

Pre −P ost flo w

Vo l ts Tim e (s ec )

W ire S peed A mps

Sequenc e Adjust Setup

2

3

4

5

7

6

10

9

8

S E T U P

V t

A

1

2

3

4

5

7

6

10

9

8

OM-212 296 Page 26

Auxiliary Menus (Continued)

• Auxiliary MenuAn auxiliary menu is provided when boththe Sequence and Setup buttons arepressed simultaneously. The Setup andSequence button LEDs flash when in theauxiliary menu. Press the Setup button toscroll forward, or press the Sequence but-ton to scroll backwards through the auxilia-ry menu.

� To exit auxiliary menu at any time,press Sequence and Setup simulta-neously.

1 CodeUpon leaving the auxiliary menu, the user isasked if a password code, indicated by“CODE” in the top display, should be acti-vated. By default, the code is off, indicatedby “OFF” in the lower display. The user mayenter a numerical password between 0 and999 by turning the Adjust control. When theuser re-enters the auxiliary menu, the pass-word code must be selected to gain accessto the auxiliary menu. A failed attempt re-turns the user to the weld screen and acounter will increment. The counter in theprogram display shows the number of in-correct attempts. The user has five at-tempts to enter the correct password codebefore being locked out of the auxiliarymenu, indicate by “LOCK”, in the lower dis-play. After five failed attempts, the powermay be cycled to continue welding, but theuser will remained locked out of the auxilia-ry menu. Pressing the Program, Sequence,upper display, and Setup buttons simulta-neously resets the counter to zero (0),asshown in the weld screen. When the count-er is reset,“CODE” is shown in the upperdisplay, and “RESET” in the lower display.Pressing the Program, Sequence, upperdisplay, and Setup buttons simultaneouslyagain, will reset the unit to the factory de-faults (see Section on Reset To FactorySettings), indicated by “WIPE” in the upperdisplay. Resetting the unit will also turn offthe password code feature.2 Power Source SelectionThe upper display shows “PSS”. The lowerdisplay shows “ON” or “OFF”. Use Adjustcontrol to select “ON” or “OFF”.3 Voltage Range LockVoltage range lock is active when “LOCK”is shown in the lower display and the VoltsLED is lit. The voltage range lock is off bydefault, and is confirmed by “OFF” beingshown in the upper display. To set a voltagevariance between 0 to 10 volts from presetvoltage, press the upper display button androtate the Adjust control to the desired volt-age. The voltage range lock is program de-pendent, a different voltage variance maybe locked in for each program and indepen-dent from the wire feed speed and amper-age lock.

� If locks are applied, only those pro-grams with locks are accessible.

4 Amperage Range LockThe amperage range lock is indicated by“LOCK” in the upper display and a lit AmpsLED. The amperage range lock is set to off,indicated by “OFF” in the lower display or0.0 to 250 amperes. The amperage rangelock is program dependant and indepen-dent for wire feed speed or voltage lock.5 Wire Feed Speed Range LockThe wire feed speed range lock is indicatedby “LOCK” in the upper display and a litWire Speed LED. The wire feed speedrange lock is off by default, and “OFF” isshown in the lower display. To set a wirefeed speed variance between 0 to 250 ipm(0 to 6.3 mpm) from the preset wire feedspeed, press the lower display button andturn the Adjust control until the desired wirefeed speed variance is set. The wire feedspeed range lock is program dependent, adifferent wire feed speed variance may beset for each program and independent offrom voltage and amperage locks.

� If locks are applied, only those pro-grams with locks are accessible.

6 Number of ProgramsThe number of programs is indicated by“NUMB” is shown in the upper display and“PROG” is shown in the lower display. Theactive program number (1 through 12) isshown in the Program display. Use the Ad-just control to change the active program.

� If locks are active, only those programswith locks are accessible.

7 Wire Touch Sense RetractWhen wire touch sense is enabled (seeSection 6-7), the wire touch sense retracttime determines the amount of time the wirewill retract from the workpiece for a fixedwirespeed. To set the wire touch retracttime, turn the Adjust control until the desiredwire touch sense retract time is set.8 Wire Drive Motor TypeThere are four types of motor drives avail-able, RAD−400 with tach, RAD−400 with-out tach, RAD−780 with tach, andRAD−780 without tach. When selecting theRAD−400 with tach, ”RAD” will be dis-played in the upper display and ”400” will bedisplayed in the lower display. When select-ing the RAD−780 with tach, ”RAD” will bedisplayed in the upper display and ”780” willbe displayed in the lower display. When se-lecting the RAD−400 without tach orRAD−780 without tach, ”NO” will be dis-played in the upper display and ”TACH” willbe displayed in the lower display.9 Wire Drive Motor DirectionThe motor direction is indicated by ”MOTR”is displayed in the upper display and ”RIGT”

or ”LEFT” is displayed in the lower display.Changing between ”RIGT” and ”LEFT”changes the direction of the motor.

10 Parallel Kits

The number of paralleling kits is indicatedby ”PRLL” in the upper display, ”KITS” in thelower display, and the number of kits in theProgram Display. When paralleling twopower sources with a Miller Paralleling Kit,select ”1” in the Program Display. When us-ing one power source per HDC 1500DX,set the number of paralleling kits to ”0” in theProgram Display.

11 SB1 and SB2 Relays

The contact closure of the SB1 and SB2 isindicated by ”RLAY” in the upper display.When the HDC 1500DX is powered off, theSB1 and SB2 relay closures are open.When the HDC 1500DX is powered on, if”NOPN” is displayed in the lower display,the SB1 and SB2 relay contact closures actas normally−open. When the HDC 1500DXis powered on, if ”NCLS” is displayed in thelower display, the SB1 and SB2 relay con-tact closures act as normally−closed.

12 Arc Time

Arc time is active when “HR” is shown in theprogram display. Actual arc time in hoursand minutes, is shown in the upper display,wrapping to the lower display.

13 Cycles

Arc cycles is active when “CL” is shown inthe program display. The arc cycle count isshown in the upper display, wrapping to thelower display.

14 Software Revision Level

When “DREV” is shown in the upper dis-play, control board PC20 revision level isshown in the lower display. Press the upperdisplay button and “MERV” will now be dis-played in the upper display, and the motorcontrol board PC1 revision level will be dis-played in the lower display.

15 Reset To Factory Settings

To access reset menu and reset factory de-fault settings, proceed as follows: simulta-neously press the Program, Sequence, up-per display, and setup buttons. “WIPE” isdisplayed on the upper display, and “OFF”is displayed on the lower display. The lowerdisplay button LED is also lit. Turn Adjustcontrol or push lower display button tochange lower display from “OFF” to “ON”,and simultaneously press the Program, Se-quence, upper display, and setup buttonsagain. All parameters except arc time andcycle count are now reset to factory defaultsettings.

If a reset is not desired, turn Adjust controluntil lower display shows”OFF”, and simul-taneously press the Program, Sequence,upper display, and setup buttons.

OM-212 296 Page 27

SECTION 7 − Motor Types

For the HDC 1500DX to work properly, the motor used must match the motorselected. The motor is selected in the Auxiliary Menu (see Section 6-11 on WireDrive Motor Type).

NOTE

There are currently four motors that are supported by the HDC 1500DX.

Types of Motors are:

Motor Auxiliary Menu Selection

1) RAD 400 With Tachometer RAD 400

2) RAD 780 With Tachometer RAD 780

3) RAD 400 Without Tachometer NO TACH

4) RAD 780 Without Tachometer NO TACH

When using the RAD 400 With Tachometer or RAD 780 With Tachometer, the Wire Speed shown is the speed ofthe wire in either inches−per−minute or meters−per−minute (see Section 6-7). The tachometer provides feedbackto regulate and record wire speed.

When using the RAD 400 Without Tachometer or RAD 780 Without Tachometer, the Wire Speed shown is neithera wire speed in inches−per−minute nor a wire speed in meters−per−minute, but rather a percentage of the powerprovided to the motor. Without a tachometer the HDC 1500DX is unable to either regulate or record wire speed.

Notes

OM-212 296 Page 28

SECTION 8 − Setting Sequence Parameters

8-1. 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 untilstop button is pressed.

If time is set to zero in any timed se-quence except Weld, the sequenceis 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. Postflow

X

X

X

X

X

X

X

X

0.0-10.0

0.0-5.0

0.0-600.0

0.0-5.0

0.0-5.0

0.0-10.0

Weld Time

CraterTime

PostflowTime

Time

StartTimePreflow

Time

Preflow

StartButton

Run-In Start Weld Crater

StopButton

Burnback Postflow SequenceEnd

BurnbackTime

X

X

X

X

X

OM-212 296 Page 29

8-2. Calibrating The HDC 1500DX

� The HDC 1500DX controller is cali-brated from the factory.

If using a TRUE RMS meter capableof operation over a range of 10HZ to360HZ, calibration must be done withthe power source in DC or balancedAC.

If using an AC+DC TRUE RMS metercapable of operation over a range of10HZ to 360HZ, calibration can bedone with the power source in DC,balanced AC or unbalanced AC.

This meter will be referred to as ”ex-ternal meter” in the following proce-dure. If the external meter does notmeet these requirements do not pro-ceed, as the controller will not be cali-brated correctly.

Calibration must be done with a loadbank for accurate calibration. Calibra-tion while welding is not recom-mended and is difficult as the voltageand amperage may vary sufficientlyto make calibration inaccurate.

1 HDC 1500DX Controller

2 Adjust Control Button

3 Start Button

4 Stop Button

5 Power Switch

6 Inch Down Button

7 Inch Up Button

� Turn off power source, controller,and load bank.

Attach load bank to torch and work.

Adjust load bank setting to handle 600 am-peres.

Disconnect wire drive motor from controllerat motor or control.

Turn on the power source, controller, andload bank.

In the Auxiliary Menu of the controller, se-lect NO TACH for motor type and exit theAuxiliary Menu.

Adjust the preset voltage to 30.0 volts onthe controller.

Press the START button on the controller.

Set the external meter to read voltage andplace one lead on the torch and one lead onthe work.

If using sense leads on the HDC 1500DX,adjust potentiometer P2 on the controllermotor board until the external meter readsmatches the controller voltage meter.

If not using sense leads on the HDC1500DX, adjust potentiometer P4 on thecontroller motor board until the external me-ter reads matches the controller voltagemeter.

Set the external meter to read amperageand place meter around the weld cable(s).

Adjust the voltage until the external meterreads approximately 600 amperes.

Adjust potentiometer P3 on the controllermotor board until the external metermatches the controller amperage meter.

Press the STOP button on the controller.

In the Auxiliary Menu of the controller, se-lect the correct for motor type and exit theAuxiliary Menu.

Turn off power source, controller, and loadbank.

Re−connect the wire drive motor.

Remove load bank.

3

4

56

7

1

2

OM-212 296 Page 30

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Routine Maintenance

� Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Clean andtightenweldterminals.

Repair orreplacecrackedweldcable.

Check14-pincord.

Check gashose andfittings.

Checkguncable.

Replacecrackedparts.

6 Months

Blow out or vacuuminside. During heavyservice, cleanmonthly.

ORCleandriverolls.

9-2. Circuit Breaker CB1

� Turn Off welding powersource and weld control.

1 Circuit Breaker CB1

CB1 protects the HDC 1500DX inter-nal circuits from overload. If CB1opens, all operations stop. Correctthe problem, and press button to re-set breaker.

Ref. 803 449-A

1

OM-212 296 Page 31

9-3. Troubleshooting Table

Trouble Remedy

Unit is completely inoperative. Check circuit breaker CB1, and reset if necessary (see Section 9-2).

Wire does not feed during jogging. Place Power Switch S1 in On position (see Section 6-4).

Check 115 volts ac input power and be sure it is energized.

Check circuit breaker CB1, and reset if necessary (see Section 9-2).

Jog Speed Control set too low; increase Jog Speed setting (see Section 6-7).

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 (seeSection 6-4 and Parts List).

Have Factory Authorized Service Agent check control board PC1, and replace if necessary.

Wire feeds wrong direction during jog-ging.

Change Wire Drive Motor Direction setting in the Auxiliary Menu (see Section 6-11).

Wire only feeds down whether InchDown 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 ispressed (ensure that all wire feed jog-ging functions are operating properly

Check Start switch PB1, and replace if necessary.pressed (ensure that all wire feed jog-ging functions are operating properlybefore checking this problem).

The unit will not start if in a menu screen, indicated by a blinking light.

No wire feed speed control with WireSpeed control during welding. WireSpeed remains at the Run−In WireSpeed setting.

Check current feedback signal. This signal, +1 volt DC per 100 amperes, can be measured on termi-nal strip TB1, terminal F, with respect to terminal D (see Section 5-7). HDC 1500DX needs a signal ofgreater than 1.5 volts DC i.e. > 150 amps) for the unit to go from run−in to weld parameters.

Speed setting.Have Factory Authorized Service Agent check control board PC1, and replace if necessary.

No contactor control for welding powersource (ensure that welding powersource is working properly and that allconnections are correct).

Check for contact closure from pin A to pin B. This can be measured on terminal block TB1, terminalA, with respect to terminal B (see Section 5-7).

No output control for welding powersource.

Check command signal on pin E of 14-pin receptacle. This signal can be measured on terminal blockTB1, terminal E, with respect to terminal D. Signal should go from 0 to +10 volts DC as Output controlsource. TB1, terminal E, with respect to terminal D. Signal should go from 0 to +10 volts DC as Output controlis turned from min. to max.

Unit displays BUTN EROR. Check the push buttons, and replace if necessary (see Section 6-4 and Parts List). (On power up theHDC 1500DX checks the push buttons to see if any are stuck.) Turn the unit off for 10 seconds toclear the error message.

Unit displays TACH EROR. Check connection from HDC 1500DX to motor. Turn the unit off for 10 seconds to clear the error mes-sage. This error is displayed because the HDC 1500DX is not receiving a tach signal from the motor.

Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-11).(The motor may not have a tach.)

Make sure motor cable is not routed with weld cable. (If inching works properly, noise may be corrupt-ing the tach signal.)

Unit displays MOTR EROR. Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-11).Turn the unit off for 10 seconds to clear the error message.

Inspect motor for damage. (see motor Owner’s Manual). (Motor draws excessive amount of current.)

OM-212 296 Page 32

Trouble Remedy

Unit displays GRND EROR. Welding current is present in the safety ground. Isolate welding wire and torch from any groundedequipment. 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 thesafety ground.)

Unit displays COM EROR. Make sure all connectors are properly plugged into both boards. (Motor board is not communicating toDisplay board.)

Notes

OM-212 296 Page 33

SECTION 10 − ELECTRICAL DIAGRAM

221 405-B

Figure 10-1. Circuit Diagram

OM-212 296 Page 34

SECTION 11 − PARTS LIST

� Hardware is common andnot available unless listed.

803 627-C

1

2

3

45

6

7

1415

1617

18

21

22 23

20

19

13

8

9

10

11

12

Figure 11-1. Control Box Components

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 11-1 Main Assembly

Quantity

1 214 799 Box, Enclosure HDC Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 214 808 Cover, Box Enclosure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 179 851 Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PB3, 4 202 944 Switch, Pb Mc No Spst 5a 115Vac (Gray) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PB1 202 946 Switch, Pb Mc No Spst 5a 115Vac (Green) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PB2 202 945 Switch, Pb Mc No Spst 5a 115Vac (Red) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nameplate (Order by Model and Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 S1 011 611 Switch, Tgl Dpdt 15A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 212 289 Overlay, Front Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 212 483 Overlay, Front Panel (CE Version) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 213 887 Circuit Card Assy, Switches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 212 290 Circuit Card Assy, Display/Micro W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 221 404 XFMR, Control 30Va 24V/24V/18V/18V 115 Pri 50/60 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 193 440 Switch, Ground Current Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 214 816 Spacer, Terminal Strip Bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 212 481 Block, Term 30 Amp 13 Pole Screw Term 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 214 805 Bracket, Terminal Strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 212 304 Label, Terminal Strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PC1 221 394 Circuit Card Assy, Motor Control W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 RC2 139 268 Conn, Circ Ms/Met 10Skt Size 18 Rcpt Panel Solder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 RC1 094 480 Conn, Circ Ms/Met 14Pin Size 20 Rcpt Panel Solder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 070 371 Blank, Snap−In Nyl 1.093/1.125 Mtg Hole Black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CB1 083 432 Circuit Breaker, Man Reset 1p 10A 250Vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-212 296 Page 35

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 11-1 Main Assembly (Continued)

Quantity

23 117 860 Blank, Snap−in Nyl .187 Mtg Hole Black 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 039 116 Label, High Voltage Test And Ground Ok 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 436 Label, Ground/Protective Earth 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 342 Label, Warning Electric Shock Power Still Present (Standard Version) 1. . . . . . . . . . . . . . . . . . . . . . . 217 354 Label, Warning Electric Shock Wordless (CE Version) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 591 Cable, Motor 10 Ft (10 Pin) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 836 Cable, Interconnecting 30 Ft (14 Pin) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 6/04

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

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.

LIMITED WARRANTY − Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants toits original retail purchaser that new Miller equipment sold afterthe effective date of this limited warranty is free of defects inmaterial and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due to suchdefects in material or workmanship. Miller must be notified inwriting within thirty (30) days of such defect or failure, at whichtime Miller will provide instructions on the warranty claimprocedures to be followed.

Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date that theequipment was delivered to the original retail purchaser, or oneyear after the equipment is sent to a North American distributoror eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* 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 bythe engine manufacturer.)

3. 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 TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* 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 arecovered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other thanMiller, or equipment that has been improperly installed,improperly operated or misused based upon industrystandards, or equipment which has not had reasonableand necessary maintenance, or equipment which hasbeen used for operation outside of the specifications for theequipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE ANDUSE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USE ANDMAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Miller’s option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goods atcustomer’s risk and expense. Miller’s option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION, OPERATIONOF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENTFURNISHED BY MILLER IS EXCLUDED AND DISCLAIMEDBY MILLER.

Some states in the U.S.A. do not allow limitations of how long animplied warranty lasts, or the exclusion of incidental, indirect,special or consequential damages, so the above limitation orexclusion may not apply to you. This warranty provides specificlegal rights, and other rights may be available, but may varyfrom state to state.

In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights may beavailable, but may vary from province to province.

PRINTED IN USA 2004 Miller Electric Mfg. Co. 10/04

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125

European Headquarters −United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with 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 Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Informationand Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

File a claim for loss or damage duringshipment.

For assistance in filing or settling claims, contactyour distributor and/or equipment manufacturer’sTransportation Department.

Contact your Distributor for:

To locate a Distributor or Service Agency visitwww.millerwelds.com or call 1-800-4-A-Miller