Miller DIMENSION NT 450 WCC Owner's Manual
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Miller DIMENSION NT 450 WCC Owner's Manual

Miller DIMENSION NT 450 WCC Owner's Manual

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OM-240 044C
2013−02
Processes
Multiprocess Welding
Description
Arc Welding Power Source
t
Dimension NT 450 WCC
File: Multiprocess Welding
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller DIMENSION NT 450 WCC

  • Page 1 OM-240 044C 2013−02 Processes Multiprocess Welding Description Arc Welding Power Source Dimension NT 450 WCC File: Multiprocess Welding Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 Notes...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

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

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-240 044 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Disconnect input plug or power before working on machine. Safe5 2012−05 OM-240 044 Page 11...

  • Page 16: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Serial Number And Rating Label Location The serial number and rating information for the power source is located on the front or the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 17: Volt-Ampere Curves

    4-4. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode DC Current B. CV Mode DC Current va_curve1 − 4/95 − 212 111-A / 212 112-A OM-240 044 Page 13...

  • Page 18: Selecting A Location

    4-5. Selecting A Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks Movement beyond opposite side of unit. Line Disconnect Device Locate unit near correct input pow- er supply. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 19: Dimensions And Weights

    4-6. Dimensions And Weights Dimensions 30 in. (762 mm) including lift eye 23 in. (585 mm) 38 in. (966 mm) including strain relief 35 in. (889 mm) 1-1/4 in. (32 mm) 21-1/8 in. (537 mm) 1-1/8 in. (29 mm) 7/16 in. (11 mm) Dia Weight 376 lb (171 kg) 4 Holes...

  • Page 20: Tipping

    4-7. Tipping Do not move or operate unit where it could tip. 4-8. 115 VAC Receptacle And Supplementary Protectors Turn power before connecting to receptacle. 115 V 15 A AC Receptacle RC15 Power is shared between RC15 and Remote 14 receptacle RC14 (see Section 4-12).

  • Page 21: Weld Output Terminals And Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-J 2011−07 OM-240 044 Page 17...

  • Page 22: Connecting Weld Output Cables

    4-10. Connecting Weld Output Cables Tools Needed: 3/4 in. (19 mm) 803 778-B cable terminal and copper bar. Make Weld Cable Terminal Turn off power before connecting to sure that the surfaces of the weld cable weld output terminals. Copper Bar terminal and copper bar are clean.

  • Page 23: Connecting Remote Control

    4-12. Connecting Remote Control Turn off power before con- necting to Remote 14 recep- tacle. Remote 14 Receptacle RC14 Connect remote control to RC14. C L N Ref. 800 166-D / Ref. S-0004-A / S-0750 OM-240 044 Page 19...

  • Page 24: Electrical Service Guide

    4-13. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hertz Models Input Voltage (V) Input Amperes (A) At Rated Output...
  • Page 25 Notes OM-240 044 Page 21...

  • Page 26: Connecting 3-Phase Input Power

    4-15. Connecting 3-Phase Input Power = GND/PE Earth Ground IMPORTANT Input Contactor GND/ PE Earth Ground Tools Needed: 3/8 in. 3/8 in. input3 2012−12 − Ref. 803 766-C / 800 103-C / Ref. 801 116-A OM-240 044 Page 22...
  • Page 27 4-15. Connecting 3-Phase Input Power (Continued) applicable, use lugs of proper amperage Close and secure access door on welding Installation must meet all National capacity and correct hole size. power source. and Local Codes − have only qualified persons make this installation. Welding Power Source Input Power Con- Disconnect Device Input Power Connec- nections...

  • Page 28: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls 239 918-D Power Switch feeder (with WCC inactive) modes, a remote amperage. When set to max, control in- control provides full range of unit output re- creases short-circuit amperage at low arc This unit is equipped with a fan motor that gardless of V/A Adjust control setting.

  • Page 29: Meter Functions For Cc/Cv Models

    5-2. Meter Functions For CC/CV Models The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle 78.0 Scratch Start TIG Actual Volts (OCV) Preset Amps Lift-Arc TIG (GTAW) Actual Volts Preset Amps 78.0...

  • Page 30: Section 6 − Maintenance & Troubleshooting

    SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 31: Voltmeter/Ammeter Help Displays

    6-3. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 0 Display Indicates a shorted thermistor in the transformer of the unit. If this display is shown, contact a Factory Autho- rized Service Agent.

  • Page 32: Troubleshooting

    6-4. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect device in On position (see Section NO TAG). erative; pilot light PL1 off. Check for open line fuse(s), and replace if open (see Section NO TAG). Check for proper input power connections (see Section NO TAG). Check for proper jumper link position (see Section 4-14).
  • Page 33 Notes OM-240 044 Page 29...

  • Page 34: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For Dimension NT 450 WCC OM-240 044 Page 30...
  • Page 35 239 917-B OM-240 044 Page 31...

  • Page 36: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 805 313-A Figure 8-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....Fig 8-2 PANEL, Front w/Components .
  • Page 37 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ..159 244 PRIMARY BOX (Includes), ..........
  • Page 38 Hardware is common and Hardware is common and not available unless listed. not available unless listed. 805 314-B Figure 8-2. Panel, Front With Components OM-240 044 Page 34...
  • Page 39 Item Dia. Part Description Quantity Mkgs. Figure 8-2. Panel, Front With Components (Fig 8-1 Item 1) ... . . 204 143 PANEL, FRONT ........... . .
  • Page 40 Hardware is common and not available unless listed. 803 937-D Figure 8-3. IGBT/Capacitor Assembly OM-240 044 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity 221 298 Figure 8-3. IGBT/Capacitor Assembly (Fig 8-1 item 23) ... . . 221 301 BUS PLATE, IGBT TO CAPACITOR NEGATIVE ......
  • Page 42 Hardware is common and not available unless listed. 803 936-A Figure 8-4. Panel, Rear With Components Item Dia. Part Description Quantity Mkgs. Figure 8-4. Panel, Rear With Components (Fig 8-1 Item 9) ....173 283 CHAMBER, PLENUM 14 IN .
  • Page 43 Effective January 1, 2013 (Equipment with a serial number preface of MD or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...

  • Page 44: Options And Accessories

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2013 Miller Electric Mfg. Co. 2013−01...

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