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Miller Electric Dimension NT 450, NT 500 manual

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Table of contents for the manual

  • Page 1

    Dimension NT 450 Processes Description Multiprocess W elding Arc Welding Power Source OM-2252 218 084R 2008 − 01 t Visit our website at www.MillerWelds.com File: Multiprocess Welding Dimension NT 500 t And[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    Notes[...]

  • Page 5

    OM-2252 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or[...]

  • Page 6

    OM-2252 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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 local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-2252 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard.  Do not install or place unit on, over , or near combustible surfaces.  Do not install unit near flammables.  Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this un[...]

  • Page 8

    OM-2252 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lea[...]

  • Page 9

    OM-2252 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves[...]

  • Page 10

    OM-2252 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation.  Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHA[...]

  • Page 11

    OM-2252 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non-utilisation.  V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants [...]

  • Page 12

    OM-2252 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures.  Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction.  Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures.  S’abstenir de touche[...]

  • Page 13

    OM-2252 Page 9 2-5. P r i nc ip al e s n or m e s d e sé c ur i té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , Americ[...]

  • Page 14

    OM-2252 Page 10[...]

  • Page 15

    OM-2252 Page 1 1 SECTION 3 − DEFINITIONS 3-1. General Precautionary Label W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric[...]

  • Page 16

    OM-2252 Page 12 3-2. Input Connection Label 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power [...]

  • Page 17

    OM-2252 Page 13 SECTION 4 − INST ALLA TION 4-1. Specifications Model Rated W elding Amperage/ V oltage Range Max OCV − DC Amperes Input at Rated Load Output 50/60 Hz, Three-Phase Model W elding Output V oltage Range Max OCV − DC 230 V 380 V 400 V 440 V 460 V 575 V KV A KW 450 Amp 450 A @ 38 V olts DC 100% 5 − 500A In CC Mode 78 VDC In CC Mo[...]

  • Page 18

    OM-2252 Page 14 4-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 − 4/95 − 212 1 11-A / 212 1 12-A A. CC Mode B. CV Mode 0 10 20 30 40 50 60 70 80 90 0 100 20 0 30 0 40 0 500 600 70 0 80 0 DC Current DC V oltag[...]

  • Page 19

    OM-2252 Page 15 4-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Plate Label 4 Rating Label CE Models − T ypical Use rating label to determine input power needs. 5 Line Disconnect Device Locate unit near correct input pow- er[...]

  • Page 20

    OM-2252 Page 16 4-5. Dimensions And Weights Dimensions A 30 in (762 mm) including lift eye B 23 in (585 mm) C 38 in (966 mm) including strain relief D 35 in (889 mm) E 1-1/4 in (32 mm) F 21-1/8 in (537 mm) G 1-1/8 in (29 mm) H 7/16 in (1 1 mm) Dia W eight 376 lb (171 kg) 800 453-A / 801 530 D E F G H 4 Holes A B C Front[...]

  • Page 21

    OM-2252 Page 17 4-6. Tipping ! Do not move or operate unit where it could tip. 4-7. 1 15 V AC Receptacle And Circuit Breakers Ref. 800 166-D ! T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC15 Power is shared between RC15 and Remote 14 receptacle RC14 (see Section 4-1 1). 2 Circuit Breaker CB1 3 Circuit Breaker CB2 C[...]

  • Page 22

    OM-2252 Page 18 4-8. W eld Output T erminals And Selecting Cable Sizes ! T urn Off power before T otal Cable (Copper) Length In Weld Circuit Not Exceeding ! T urn Off power b e f ore connecting to weld output terminals. 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W elding Amperes 10 ?[...]

  • Page 23

    OM-2252 Page 19 4-10. Remote 14 Receptacle Information Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB2. B Contact closure to A completes 24 volts ac contactor control circuit. 1 15 VOL TS AC I 1 15 volts ac. Protected by circuit breaker CB1. J Contact closure to I completes 1 15 volts ac contactor control cir[...]

  • Page 24

    OM-2252 Page 20 4-12. 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. 50/60 Hertz Models Input V oltage 230 380 400 440 460 575 Inp[...]

  • Page 25

    OM-2252 Page 21 4-14. Connecting Input Power 1/2 in 3/8 in T ools Needed: 800 103-C / Ref. 801 1 16-A ! Installation must meet all National and Local Codes − have only quali- fied persons make this installation. ! Disconnect and lockout/tagout in- put power before connecting input conductors from unit. ! Make input power connections to the weldin[...]

  • Page 26

    OM-2252 Page 22 SECTION 5 − OPERA TION 5-1. Controls 229 448-A 1 2 3 6 7 4 5 1 Power Switch  This unit is equipped with a fan motor that is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 5-2) 3 Ammeter (see Section 5-2) 4 Mode Switch Use Mode switch to determine both process and output On/Of f contr[...]

  • Page 27

    OM-2252 Page 23 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 Scratch Start TIG Actual V olts (OCV) Preset Amps VA 78.0 85 Lift-Arc TIG (GT AW) VA Actual V olts Preset Amps 8.0 85 Air Carbon Arc VA Actual V olts (OCV) Pre[...]

  • Page 28

    OM-2252 Page 24 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance  Maintain more often during severe conditions. ! Disconnect power before maintaining.  = Check  = Change  = Clean Δ = Repair  = Replace * T o be done by Factory Authorized Service Agent Every 3 Months  Labels  W eld T erminals Every [...]

  • Page 29

    OM-2252 Page 25 6-3. V oltmeter/Ammeter Help Displays  All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 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. 2 Help 2 Display Indicates a[...]

  • Page 30

    OM-2252 Page 26 6-4. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative; pilot light PL1 off. Place line disconnect device in On position (see Section 4-14 ). Check for open line fuse(s), and replace if open (see Section 4-14 ). Check for proper input power connections (see Section 4-14 ). Check for proper jumper link po[...]

  • Page 31

    OM-2252 Page 27 Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

  • Page 32

    OM-2252 Page 28 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram For Dimension NT[...]

  • Page 33

    OM-2252 Page 29 218 081-F[...]

  • Page 34

    OM-2252 Page 30 SECTION 8 − P ARTS LIST 803 896-E  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3 2 15 17 18 19 20 21 24 25 26 27 28 29 31 30 16 22 23 21 Figure 8-1. Main Assembly Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 Fig 8-2 P ANEL, Front w/Components 1 . . . . . [...]

  • Page 35

    OM-2252 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 14 TE1 159 244 PRIMARY BOX (Includes), 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 835 NUT , 10-32 BRASS 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-2252 Page 32 803 897-G  Hardware is common and not available unless listed.  Hardware is common and not available unless listed. 1 2 3 4 5 3 4 7 6 8 9 10 22 24 22 18 19 20 21 23 13 14 15 12 11 16 25 26 27 28 29 Figure 8-2. Panel, Front With Components[...]

  • Page 37

    OM-2252 Page 33 Figure 8-2. Panel, Front With Components (Fig 8-1 Item 1) Description Quantity Part No. Dia. Mkgs. Item No. 1 204 143 P ANEL, FRONT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POS 181 245 TERMINAL, PWR OUTPUT RED 1 . . . . . . . . . . . . .[...]

  • Page 38

    OM-2252 Page 34  Hardware is common and not available unless listed. 803 937-C 1 2 2 3 4 5 6 9 10 11 12 7 13 8 14 Figure 8-3. IGBT/Capacitor Assembly[...]

  • Page 39

    OM-2252 Page 35 Description Part No. Dia. Mkgs. 221 298 Item No. Quantity Figure 8-3. IGBT/Capacitor Assembly (Fig 8-1 item 23) 1 221 301 BUS PLA TE, IGBT TO CAP ACITOR NEGA TIVE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 221 304 ST AND − OFF , CONDUCTIVE BUS 5 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    OM-2252 Page 36  Hardware is common and not available unless listed. 1 803 936-A 2 3 4 5 6 9 7 8 10 Figure 8-4. Panel, Rear With Components Figure 8-4. Panel, Rear With Components (Fig 8-1 Item 9) Description Quantity Part No. Dia. Mkgs. Item No. 1 173 283 CHAMBER, PLENUM 14 IN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 41

    Notes[...]

  • Page 42

    Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

  • Page 44

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarter s − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F AX: 9 20-735-4125 European Headqua rters −[...]