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OM-240 044 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2011−10

7

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
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.

NOTICE − Indicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.

1-2.

Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or  severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded 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 mats
or covers big enough to prevent any physical contact with the work
or ground.

Do not use AC output in damp areas, if movement is confined, or if
there 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 on
unit.

Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.

Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

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

Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.

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 directly
with a separate cable.

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

Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.

Use only well-maintained equipment. Repair or replace damaged
parts 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 workpiece
or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.

Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.

SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.

Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-
ment.

To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

Содержание DIMENSION NT 450 WCC

Страница 1: ...Dimension NT 450 WCC Processes Description Multiprocess Welding Arc Welding Power Source OM 240 044C 2013 02 t Visit our website at www MillerWelds com File Multiprocess Welding...

Страница 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Страница 3: ...INSTALLATION 12 4 1 Serial Number And Rating Label Location 12 4 2 Specifications 12 4 3 Duty Cycle And Overheating 12 4 4 Volt Ampere Curves 13 4 5 Selecting A Location 14 4 6 Dimensions And Weights...

Страница 4: ...Notes...

Страница 5: ...ings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use t...

Страница 6: ...tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as...

Страница 7: ...PARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for mai...

Страница 8: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Healt...

Страница 9: ...demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D autres consignes de s curit sont n cessaires d...

Страница 10: ...ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoque...

Страница 11: ...t rieur Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim...

Страница 12: ...seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les...

Страница 13: ...t Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Re...

Страница 14: ...OM 240 044 Page 10...

Страница 15: ...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 powe...

Страница 16: ...50 60 Hz Three Phase 230 V 460 V 575 V KVA KW 450 Amp 450 A 38 Volts DC 100 Duty Cycle 5 500A In CC Mode 78 VDC In CC Mode For 60 Hz 57 2 18 29 1 04 23 0 84 22 6 0 87 21 0 0 29 10 38V In CV Mode 78 V...

Страница 17: ...erage output capabilities of unit Curves of other settings fall be tween curves shown va_curve1 4 95 212 111 A 212 112 A A CC Mode B CV Mode 0 10 20 30 40 50 60 70 80 90 0 100 200 300 400 500 600 700...

Страница 18: ...unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volat...

Страница 19: ...sions 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 11 mm Dia Weight 376 lb 171...

Страница 20: ...cting to receptacle 1 115 V 15 A AC Receptacle RC15 Power is shared between RC15 and Remote 14 receptacle RC14 see Section 4 12 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects...

Страница 21: ...1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x...

Страница 22: ...h nut so that weld cable terminal is tight against copper bar Tools Needed 3 4 in 19 mm 4 2 3 1 5 6 4 11 Remote 14 Receptacle Information Socket Socket Information 24 VOLTS AC A 24 volts AC Protected...

Страница 23: ...4 12 Connecting Remote Control Ref 800 166 D Ref S 0004 A S 0750 Turn off power before con necting to Remote 14 recep tacle 1 Remote 14 Receptacle RC14 Connect remote control to RC14 A J B K I C L N H...

Страница 24: ...me current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60...

Страница 25: ...OM 240 044 Page 21 Notes...

Страница 26: ...5 Connecting 3 Phase Input Power input3 2012 12 Ref 803 766 C 800 103 C Ref 801 116 A 3 8 in 3 8 in Tools Needed IMPORTANT GND 3 PE Earth Ground Input Contactor L1 L2 L3 GND PE Earth Ground 8 5 4 2 11...

Страница 27: ...Reed Switch Ground Current Sensor Optional Connect green or green yellow grounding conductor to welding power source ground ing terminal first If unit is equipped with op tional ground current sensor...

Страница 28: ...feeder with WCC Panel Remote switch should be set to Panel position 6 V A Voltage Amperage Adjust Control With Mode switch in any Stick or TIG position use control to adjust amperage from 5 to 500 amp...

Страница 29: ...d Preset Volts Blank V A 78 0 5 3 Lift Arc TIG Procedure For CC CV Models With Mode switch in the Lift Arc TIG position start an arc as follows 1 TIG Electrode 2 Workpiece Touch tungsten electrode to...

Страница 30: ...Authorized Service Agent Every 3 Months Labels Weld Terminals Every 3 Months Cables And Cords Every 6 Months Durning heavy service clean monthly 6 2 Fuse F1 Ref 800 101 C Disconnect input power be for...

Страница 31: ...stage occurs when the primary voltage drops more than 20 below the linked primary voltage setting for more than 30 seconds A constant HELP 6 message is displayed and weld output is disabled Once the...

Страница 32: ...aximum or mini mum weld output Check position of Panel Remote control switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 front panel display board PC2 and hall device...

Страница 33: ...OM 240 044 Page 29 Notes...

Страница 34: ...OM 240 044 Page 30 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram For Dimension NT 450 WCC...

Страница 35: ...OM 240 044 Page 31 239 917 B...

Страница 36: ...bly Quantity 1 Fig 8 2 PANEL Front w Components 1 2 217 136 LABEL WARNING ELECTRIC SHOCK 2 3 179 432 PANEL SIDE 2 4 179 431 COVER TOP 1 5 213 898 BAFFLE AIR UPPER IGBT ASSY 1 6 162 830 LIFT EYE 1 7 17...

Страница 37: ...179 276 BUSHING SNAP IN NYL 1 000 ID X 1 375 MTG HOLE CENT 1 24 Fig 8 3 ASSEMBLY IGBT CAPACITOR 1 25 C9 196 143 CAPACITOR POLYP MET FILM 16 F 400 VAC 10 1 26 234 503 COVER IGBT CAPACITOR ASSEMBLY 1 2...

Страница 38: ...ardware is common and not available unless listed Hardware is common and not available unless listed 1 2 3 4 5 4 6 7 8 9 10 12 11 13 14 15 31 16 17 18 20 21 22 23 24 25 15 19 29 3 30 26 27 28 Figure 8...

Страница 39: ...NG CLIP 21 4 20 NAMEPLATE ORDER BY MODEL AND SERIAL NUMBER 1 21 218 080 PANEL FRONT UPPER 1 22 190 512 STAND OFF NO 6 32 X 640 LG 250 HEX AL FEM 4 23 PC2 239 653 CIRCUIT CARD ASSY FRONT PANEL DISPLAY...

Страница 40: ...OM 240 044 Page 36 Hardware is common and not available unless listed 803 937 D 1 2 2 3 4 5 6 7 14 8 9 10 13 12 11 Figure 8 3 IGBT Capacitor Assembly...

Страница 41: ...010 494 BUSHING SNAP IN NYL 1 375 ID X 1 750 MTG HOLE 2 8 224 144 BUS BAR IGBT OUTPUT W FINS 1 9 223 387 ASSY HEAT SINK 600A IGBT 1 10 TH2 188 431 THERMISTOR NTC 30K OHM 25 DEG C 27IN LEAD 1 11 010 54...

Страница 42: ...RY 2 5 162 818 DOOR ACCESS PRIMARY 1 6 217 733 LABEL WARNING ELECTRIC SHOCK INPUT POWER EN FR 1 7 602 177 SCREW SET 250 20 X 250KNRLPT SCH STL 2 8 124 274 BRACKET MTG FAN MOTOR 1 9 FM 208 402 MOTOR 1...

Страница 43: ...lies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard...

Страница 44: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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