Miller Electric NT 456 CC manual

NT 456 CC/CV Processes Description Multiprocess W elding Arc Welding Power Source OM-2243 212 1 13T 2007 − 10  File: Multiprocess V isit our website at www.MillerWelds.com[...]

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[...]

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

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OM-2243 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[...]

OM-2243 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 [...]

OM-2243 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[...]

OM-2243 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[...]

OM-2243 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[...]

OM-2243 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[...]

OM-2243 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 [...]

OM-2243 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[...]

OM-2243 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[...]

OM-2243 Page 10[...]

OM-2243 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Nameplate Safety Symbols 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from welding electrode or wiring can kill. 3 Sparks from arcing electrode can cause explosion or fire − disconnect cable for process not in use. 4 Read Owner ’ s Manual for connect[...]

OM-2243 Page 12 SECTION 4 − INST ALLA TION 4-1. Specifications Model Rated W elding Output Amperage/V oltage Range Max OCV − DC Amperes Input at Rated Load Output 60 Hz, Three-Phase Model O utput Range Max OCV − DC 230 V 460 V 575 V KV A KW 450 Amp 450 A @ 38 V olts DC 100% Duty 5 − 500A In CC Mode 78 VDC In CC Mode 58 29 23 22.8 21.4 450 A[...]

OM-2243 Page 13 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[...]

OM-2243 Page 14 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 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input pow- er supply . ! Special installation may [...]

OM-2243 Page 15 4-5. Dimensions And Weights Dimensions A 32-1/2 in (826 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[...]

OM-2243 Page 16 4-6. Tipping ! Be careful when placing or moving unit over uneven surfaces. 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 [...]

OM-2243 Page 17 4-8. W eld Output T erminals And Selecting Cable Sizes ! T u rn 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 ?[...]

OM-2243 Page 18 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[...]

OM-2243 Page 19 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. 60 Hertz Models Input V oltage 230 460 575 Input Amperes At R[...]

OM-2243 Page 20 4-14. Connecting Input Power 800 103-C / Ref. 801 1 16-A 3/8 in 3/8 in T ools Needed: ! Installation must meet all National an d 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 weldi[...]

OM-2243 Page 21 SECTION 5 − OPERA TION 5-1. Controls 229 450-A 1 6 7 4 8 2 3 5 1 Power Switch  This unit is equipped with a fan motor that is thermostatically controlled and only runs when cooling is needed (fan-on-de- mand). If unit is not equipped with fan-on- demand, fan motor runs when power is on. 2 V oltmeter (see Section 5-2) 3 Ammeter [...]

OM-2243 Page 22 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 TIG (GT A W) Blank Preset Amps VA 85 MIG [...]

OM-2243 Page 23 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 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , and slowly lift electrode. An arc will form when electrode is lifted. Normal ope[...]

OM-2243 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 [...]

OM-2243 Page 25 6-3. V oltmeter/Ammeter Help Displays  Al l 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 [...]

OM-2243 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[...]

OM-2243 Page 27 SECTION 7 − ELECTRICAL DIAGRAM 223 809-D Figure 7-1. Circuit Diagram For NT 456 CC/CV Models[...]

OM-2243 Page 28 SECTION 8 − P ARTS LIST 803 621-C  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 21 23 24 25 26 27 28 29 31 30 16 22 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 . . . . . [...]

OM-2243 Page 29 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-2243 Page 30 803 623-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 23 22 24 11 13 12 15 16 18 19 20 21 17 14 25 26 27 28 29 12 30 Figure 8-2. Panel, Front With Components[...]

OM-2243 Page 31 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 . . . . . . . . . . . . .[...]

OM-2243 Page 32  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[...]

OM-2243 Page 33 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 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-2243 Page 34  Hardware is common and not available unless listed. 1 ST-800 707-C 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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[...]

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