Miller | LJ470011G | Owner Manual | Miller PROHEAT 35 CE (48 V COOLER) 907271, 907298, 907432 User manual

Miller PROHEAT 35 CE (48 V COOLER) 907271, 907298, 907432 User manual
OM-222 166L
2008−11
Processes
Induction Heating
Description
Induction Heating Power Source
ProHeat 35 CE
Visit our website at
www.MillerWelds.com
File: Induction Heating
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue 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 the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
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. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Warning Label Definitions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number and Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting 3-Phase Input Power For 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting 3-Phase Input Power For 400/460 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Temperature Recorder Receptacle RC9 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Temperature Recorder Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Locating Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Attaching Welded Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Using Contact Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Placing Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
3
3
4
4
4
5
6
6
6
7
7
8
9
9
10
10
10
10
11
11
12
13
14
15
15
16
16
17
18
18
20
21
21
22
22
TABLE OF CONTENTS
SECTION 6 − SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Power Source/System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1. Temperature-Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1-1. Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1-2. Bake-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1-3. PWHT (Post-Weld Heat Treat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-1-4. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5-1. Temperature Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5-1-2. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Real-Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. System Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Calibration Verification Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Calibration Verification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3-1. Initial Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3-2. TC Input/Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3-3. Finishing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − DIAGNOSTICS & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Operator Interface Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Limit Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Fault Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. System Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Removing Wrapper and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
23
23
23
23
25
25
25
26
26
27
31
32
32
32
32
33
33
33
34
36
37
37
38
38
38
38
38
43
43
43
44
44
45
45
46
46
47
47
48
50
51
52
54
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that
the product(s) identified in this declaration conform to the essential requirements and
provisions of the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
PROHEAT 35 W/TEMPERATURE CONTROL 400­460­V, CE
907298
Council Directives:
S
2006/95/EC Low Voltage
S
2004/108/EC Electromagnetic Compatibility
S
2006/42/EEC Machinery Directive
Standards:
S
IEC 60974-1 Arc Welding Equipment - Welding Power Sources: edition 3, 2005-07.
S
IEC 60974-10 Arc Welding Equipment Electromagnetic Compatibility Requirements: edition 1.1,
2004-10.
US Signatory:
November 26, 2008
__________________________________________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
240667­A
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2007−04
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 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 explained 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 symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Induction Heating 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.
D
When making input connections, attach proper grounding
conductor first − double-check connections.
D
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.
D
D
D
D
D
During operation, keep everybody, especially children, away.
D
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine
internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard.
D
Do not touch live electrical parts.
D
Enclose any connecting bus bars and coolant fittings to prevent
unintentional contact.
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.
D
D
D Additional safety precautions are required when any of the following 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 unavoidable or accidental contact with the workpiece or ground. For these
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not
work alone!
D Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
D Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
D Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
D 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.
D
D
Do not drape cables over your body.
Do not touch power circuit if you are in contact with the work, ground,
or another power circuit from a different machine.
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.
SIGNIFICANT DC VOLTAGE exists in inverter-type
power sources after removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
FUMES AND GASES can be hazardous.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
D
D
D
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation to remove fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson nearby. Fumes and gases from heating can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
Do not heat in locations near degreasing, cleaning, or spraying operations. The heat can react with vapors to form highly toxic and
irritating gases.
Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and while wearing an airsupplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if overheated. See coating MSDS
for temperature information.
OM-222 166 Page 1
FIRE OR EXPLOSION hazard.
D
D
D
D
D
D Do not overheat parts.
D Watch for fire; keep extinguisher nearby.
D Keep flammables away from work area.
Do not locate unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not operate where the atmosphere may contain flammable
dust, gas, or liquid vapors (such as gasoline).
After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
INDUCTION HEATING can cause burns.
D Hot parts and equipment can injure.
D Do not touch or handle induction head/coil
during operation.
D Do not touch hot parts bare-handed.
D
D
Allow cooling period before handling parts or equipment.
Keep metal jewelry and other metal personal items away from
head/coil during operation.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury.
D
STATIC (ESD) can damage PC boards.
D Use handle and have person of adequate
physical strength lift unit.
D Move unit with hand cart or similar device.
D For units without a handle, use equipment of
adequate capacity to lift unit.
When using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of unit.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
FLYING METAL OR DIRT can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
D
D
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
D
D
D
Have only qualified person familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.
1-4. California Proposition 65 Warnings
Welding 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 lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
OM-222 166 Page 2
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario,
Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044,
website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
1-6. EMF Information
Considerations About Induction Heating And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields − Background Paper, OTABP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow
us to draw definite conclusions about questions of possible risk or to of-
fer clear science-based advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
1. Arrange output cable to one side and away from the operator.
2. Do not coil or drape output cable around the body.
3. Keep power source and cable as far away from the operator as
practical.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If
cleared by your doctor, then following the above procedures is recommended.
OM-222 166 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom _2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-5. Veuillez lire et respecter toutes
ces normes de sécurité.
D
D
D
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
D
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
D
Le contact de composants électriques peut provoquer des accidents mortels ou des brûlures graves.
Le circuit électrique et les barres collectrices ou les
connexions de sortie sont sous tension lorsque
l’appareil fonctionne. Le circuit d’alimentation et les circuits internes
de la machine sont également sous tension lorsque l’alimentation est
sur marche. Des équipements installés ou reliés à la borne de terre de
manière incorrecte sont dangereux.
D
D
D
Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et revérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à
nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Ne pas toucher le circuit électrique si l’on est en contact avec la pièce, la terre ou le circuit électrique d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
D
D
Ne pas toucher aux pièces électriques sous tension.
Protéger toutes les barres collectrices et les raccords de refroidissement pour éviter de les toucher par inadvertance.
D
D
D
Porter des gants isolants et des vêtements de protection secs et
sans trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
D
D
D
D
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si
l’on porte des vêtements mouillés ; sur des structures métalliques telles
que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact
inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces
conditions, voir ANSI Z49.1 énuméré dans les normes de sécurité.
En outre, ne pas travailler seul !
Couper l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation selon
la norme OSHA 29 CFR 1910.147(se reporter aux Principales normes de sécurité).
N’utiliser que des tuyaux de refroidissement non conducteurs ayant
une longueur minimale de 457 mm pour garantir l’isolation.
OM-222 166 Page 4
D
Avant de toucher des organes internes, couper l’onduleur,
débrancher l’alimentation et décharger les condensateurs
d’alimentation conformément aux instructions indiquées dans la
partie maintenance.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le chauffage à induction de certains matériaux,
adhésifs et flux génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour votre santé.
D
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces
vapeurs.
D
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz.
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les adhésifs, les
flux, les métaux, les consommables, les revêtements, les nettoyants
et les dégraisseurs.
D
D
D
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz provenant du
chauffage peuvent déplacer l’air, abaisser le niveau d’oxygène et
provoquer des lésions ou des accidents mortels. S’assurer que l’air
ambiant ne présente aucun danger.
Ne pas chauffer dans des endroits se trouvant à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur
peut réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas surchauffer des métaux munis d’un revêtement tels que
l’acier galvanisé, plaqué au plomb ou au cadmium, à moins que le
revêtement ne soit enlevé de la zone chauffée, que la zone soit bien
ventilée et, si nécessaire, en portant un respirateur. Les revêtements et
tous les métaux contenant ces éléments peuvent dégager des fumées
toxiques s’ils sont surchauffés. Voir les informations concernant la
température dans les spécifications de revêtement MSDS.
Stocker des produits inflammables hors de la zone de travail.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces
inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas faire fonctionner l’appareil si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par
exemple).
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace
d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D
D
D
D
D
D
LE CHAUFFAGE PAR INDUCTION peut
provoquer des brûlures.
D Des pièces ou de l’équipement chaud peuvent
provoquer des blessures.
D
Ne pas toucher ou manipuler la tête/l’enroulement à induction pendant le fonctionnement.
D
D
Ne pas toucher des parties chaudes à mains nues.
Laisser refroidir les composants ou équipements avant de les manipuler.
Tenir les bijoux et autres objets personnels en métal éloignés de la
tête/de l’enroulement pendant le fonctionnement.
D
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas surchauffer les composants .
D Attention aux risques d’incendie: tenir un extincteur à proximité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LA CHUTE
blesser.
D
D
DE
L’APPAREIL
LES CHAMPS MAGNETIQUES peuvent
affecter des implants médicaux.
peut
D Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever l’appareil.
D Déplacer l’appareil à l’aide d’un chariot ou d’un
engin similaire.
Pour les appareils sans poignée utiliser un équipement d’une capacité appropriée pour soulever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Porter des lunettes de sécurité à coques latérales ou un écran facial.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
D Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
D Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D
SUR-
D Prévoir une période de refroidissement
D Réduire le courant de sortie ou le facteur de marche avant de recommencer le chauffage.
Respecter le cycle opératoire nominal.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes PC.
OM-222 166 Page 5
LE RAYONNEMENT HAUTE FRÉQUENCE (HF) risque de provoquer
des interférences.
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipements de radio-navigation et de communication,
les services de sécurité et les ordinateurs.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
LIRE LES INSTRUCTIONS.
D Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants).
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org et www.sparky.org).
Code électrique du Canada, partie 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (téléphone : 800-463-6727 ou en Toronto416-747-4044,
site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 25
West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).
2-6. Information EMF
Considérations relatives au chauffage à induction et aux effets des champs
électriques et magnétiques basse fréquence.
Le texte suivant est extrait des conclusions générales Département du
Congrès U.S., Office of Technology Assessment, Effets biologiques des
champs magnétiques et électriques basse fréquence − Background Paper,
OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . on dispose maintenant d’importantes découvertes scientifiques
reposant sur des expériences effectuées dans le domaine cellulaire et
des études réalisées sur des animaux et des personnes qui démontrent
clairement que des champs magnétiques basse fréquence peuvent
avoir une interaction et produire des changements dans les systèmes
biologiques. Alors que la plus grande partie de cet ouvrage est d’une très
grande qualité, les résultats sont complexes. La compréhension scientifique courante ne nous permet pas encore d’interpréter la preuve fournie
dans un seul ouvrage cohérent. Il est encore plus frustrant de ne pas
pouvoir tirer des conclusions définitives en ce qui concerne les problèmes
de risque possible ou de proposer des recommandations scientifiques
OM-222 166 Page 6
claires pour des stratégies à suivre en vue de minimiser ou de prévenir
des risques potentiels.”
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
4. Disposer le câble de sortie d’un côté à distance de l’opérateur
5. Ne pas enrouler ou draper le câble électrique autour du corps.
6. Placer la source de courant et le câble le plus loin possible de
l’opérateur.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
2
2.1
2.2
3
3.1
3.2
4
4.1
4.2
4.3
5
5.1
6
7
Electric shock from wiring can
kill.
Wear dry insulating gloves.
Do not wear wet or damaged
gloves.
Disconnect input plug or
power before working on
machine.
Induction heating can cause
injury or burns from hot items
such as rings, watches, or
parts.
Do not wear metal jewelry and
other metal personal items
such as rings and watches
during operation.
Do not touch hot parts or hot
head/coil.
Induction heating sparks can
cause fire. Do not overheat
parts and adhesives.
Keep flammables away from
heating operation. Do not heat
near flammables.
Heating sparks can cause
fires. Have a fire extinguisher
nearby and have a
watchperson ready to use it.
Breathing heating fumes can
be hazardous to your health.
Read Material Safety Data
Sheets (MSDSs) and
manufacturer’s instructions for
material used.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Always wear safety glasses
or goggles during and around
heating operations to prevent
possible injury.
Wear either safety glasses or
full goggles depending on
type of operation and nearby
processes.
Do not remove or paint over
(cover) the label.
Become trained and read the
instructions before working on
the machine or heating.
190 025
OM-222 166 Page 7
3-2. Warning Label Definitions (Continued)
1
2
1
3
2
3
4
5
6
5
4
7
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Overuse can cause
overheating. Follow rated duty
cycle.
Disconnect input plug or
power before working on
machine.
Become trained and read the
instructions before working on
the machine.
Connect green or
green/yellow grounding
conductor to ground terminal.
Connect input conductors (L1,
L2 And L3) to line terminals.
6
7
194 466
1
2
3
4
1
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Do not touch input
capacitor(s). Allow time for
capacitor(s) to discharge.
Check input capacitor(s)
voltage (see Section 9-7).
227 085-A
OM-222 166 Page 8
3-3. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
3-4. Symbols And Definitions
. Some symbols are found only on CE products.
A
IP
Amperes
Degree Of
Protection
V
Hz
Increase
Volts
Alternating Current
Hertz
Circuit Protection
Line Connection
I1
Primary Current
X
Duty Cycle
Output
I2
Rated Current
U1
Primary Voltage
U2
Load Voltage
Read Instructions
Three Phase Static
Frequency Converter-Transformer-Frequency Converter
I1max
Rated Maximum
Supply Current
P1max
Maximum Power
Consumption
Three Phase
Percent
Remote
Panel/Local
High Temperature
Voltage Input
Off
On
OM-222 166 Page 9
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 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. Specifications
Output
Frequen
cy
5 To 30
kHz
Rated Output
Single
Output
Dual
Output
35 kW At
100%
Duty
Cycle
350 A
(RMS),
700 V
(RMS)
35 kW At
100%
Duty
Cycle
700 A
(RMS),
700 V
(RMS)
Required
Reflective
Inductance
Amperes Input at
Rated Load Output
50 or 60 Hz,
Three-Phase
400 V
2.5 To 50
μh
60 A
460 V
50 A
575 V
40 A
kVA
39
Overall
Dimensions
Weight
IP
Rating
Length: 36-3/4 in
(993 mm)
Width: 21-1/2 in
(546 mm)
Height: 29 in
(737 mm)
227 lb
(103 kg)
23CM
kW
37
Storage Temperature Range −40_ F (−40_ C) to 122_ F (50_ C)
*While idling
4-3. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
Line Disconnect Device
Locate unit near correct input
power supply.
!
OR
2
Location And Airflow
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
3
12 in
(305 mm)
18 in
(460 mm)
12 in
(305 mm)
18 in
(460 mm)
OM-222 166 Page 10
803 992-B
4-4. Tipping
!
Do not move or operate unit
where it could tip.
4-5. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50 Hz
Three
Phase
Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2
Normal Operating
3
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
1
2
3
4
60 Hz Three Phase
400
460
575
60
50
40
70
61
45
80
70
60
6
8
8
254
(77)
214
(65)
334
(102)
8
8
10
1
Reference: 2005 National Electrical Code (NEC) (including article 630)
If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
Time-Delay fuses are UL class RK5 .
Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and above).
Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-222 166 Page 11
4-6. Connecting 3-Phase Input Power For 460/575 Volt Models
GND/PE Earth Ground
3
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input
conductors from unit.
!
Make input power connections to
the welding power source first.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
8
7
. The circuitry in this unit automatically
adapts the power source to the
primary voltage being applied. Check
input voltage available at site. This
unit can be connected to either 460 or
575 VAC input power.
10 See rating label on unit and check input
voltage available at site.
9
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section NO TAG. Conductors must comply with national, state, and local electrical
codes. If applicable, use lugs of proper
amperage capacity and correct hole size.
4
6
Welding Power Source Input Power
Connections
2
Strain Relief
Route conductors (cord) through strain relief and tighten screws.
3
4
1
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first.
5
6
Welding Power Source Line
Terminals
Input Conductors L1 (U), L2 (V) And
L3 (W)
Connect input conductors L1 (U), L2 (V)
and L3 (W) to welding power source line
terminals.
2
Close and secure access door on welding
power source.
Disconnect Device
Connections
7
8
3
9
4
Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply)
Grounding Terminal
Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V)
And L3 (W) to disconnect device line
terminals.
10 Over-Current Protection
Tools Needed:
Select type and size of over-current
protection using Section NO TAG (fused
disconnect switch shown).
3/8 in
803 994-C
OM-222 166 Page 12
Power
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
6
5
Input
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
4-7. Connecting 3-Phase Input Power For 400/460 Volt Models
Tools Needed:
3/8 in
3
= GND/PE Earth Ground
8
10
7
L1
4
L2
L3
9
6
5
3
4
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit.
Ref. 804 430-A
Select size and length of conductors using
Section NO TAG. Conductors must comply
with national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
Disconnect Device Input Power Connections
7
Disconnect Device (switch shown in
OFF position)
Welding Power Source Input Power Connections
8
Disconnect Device (Supply) Grounding
Terminal
Make input power connections to the
welding power source first.
2
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
3
4
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
circuitry in this unit automatically
adapts the power source to the primary
voltage being applied. Check input
voltage available at site. This unit can be
connected to either 400 or 460 VAC input
power.
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
See rating label on unit and check input voltage available at site.
Connect input conductors L1 (U), L2 (V) and
L3 (W) to welding power source line terminals.
1
Close and secure access door on welding
power source.
Input Power Conductors (Customer
Supplied Cord)
1
2
!
. The
6
5
6
Welding Power Source Line Terminals
Input Conductors L1 (U), L2 (V) And L3
(W)
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection
using Section NO TAG (fused disconnect
switch shown).
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
OM-222 166 Page 13
4-8. Power Source Output Connections
2
1
Dual Air-Cooled
Output Connection
2
1
2
1
4
4
Dual Liquid-Cooled
Output Connection
2
Single Air-Cooled
Output Connection
2
Single Liquid-Cooled
Output Connection
2
1
5
1
5
1
5
3
4
3
Ref. 803 993-C / Ref. 804 217-A
1
Output Connector 1
Single Air-Cooled Output Connection
2
Output Connector 2
3
Protective Plug
Connect air-cooled output extension cable
to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.
4
Air-Cooled Extension Cable
Single Liquid-Cooled Output Connection
5
Liquid-Cooled Extension Cable
Connect liquid-cooled output extension
cable to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.
The power source is capable of single or
dual output. When connected for single
power output, up to 35 kW is available at
the single output connection. When
connected for dual power, output power is
divided between the two output
connections.
!
Do not move or disconnect cables
while output is on.
OM-222 166 Page 14
. Blankets must be the same size.
Dual Liquid-Cooled Output Connection
Connect liquid-cooled output extension
cables to Output Connector 1 and Output
Connector 2.
. Extension cables must be the same
length: 10 ft (3 m), 25 ft (7.6 m), or 50
ft (15.2 m).
Dual Air-Cooled Output Connection
. Heating
Connect air-cooled output extension
cables to Output Connector 1 and Output
Connector 2.
. Total length of heating and extension
. Extension cables must be the same
length: 25 ft (7.6 m), 50 ft (15.2 m), or
75 ft (22.8 m).
cables must be the same
length: 30ft (9.1 m), 50 ft (15.2 m), 80ft
(24.2 m), or 140 ft (42.7 m).
cables must not exceed 360 ft (110 m).
The extension cable is counted twice
the length because it has a supply and
return hose.
4-9. Remote 14 Receptacle RC14 Information and Connections
3
A
B
2
K
C L N
D M
1
E
J
1
2
3
4
Plug
Threaded Collar
Keyway
Remote 14 Receptacle RC14
(See Section 4-10)
To connect to receptacle, align keyway, insert plug and tighten
threaded collar.
4
I
H
F
G
2
1
803 993-C
4-10. Remote 14 Socket Information
Socket
A
B
Socket Information
Remote Contactor
E
Remote Output Control
Control circuit common.
Input command signal (potentiometer wiper or 0 to +10 volts dc).
Not used.
G
F, J
Contact closure to A completes 24 volts dc contactor control circuit.
Command reference; +10 volts dc.
C
D
+24 volts dc.
Power Source Limit
Absence of internal contact closure between F and J signals power source error to remote
control device.
H
Not used.
I
Actual frequency output signal (1 volt/10 kHz).
L
M
Remote Metering
Average power output signal (1 volt/10 kW).
Voltage output signal RMS (1 volt/100 volts).
N
Total current output signal RMS (1 volt/100 amperes).
K
Chassis common.
OM-222 166 Page 15
4-11. Temperature Recorder Receptacle RC9 Information And Connections
3
2
1
2
3
Plug
Threaded Collar
Temperature Recorder
Receptacle RC9 (See Section
4-12)
To connect to receptacle, insert
plug and tighten threaded collar.
1
2
1
803 993-C
4-12. Temperature Recorder Socket Information
Socket No.
Socket Information
1
Thermocouple No. 1 (TC1), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
2
Thermocouple No. 2 (TC2), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
3
Thermocouple No. 3 (TC3), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
4
Thermocouple No. 4 (TC4), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
5
Signal Common
6
Thermocouple No. 5 (TC5), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
7
Thermocouple No. 6 (TC6), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
8
Unused
9
Unused
10
Chassis Ground
11
Unused
12
Unused
13
Unused
14
Unused
* The voltage to temperature calculation is:
(DC Volts Out x 155) − 50 = °F
(DC Volts Out x 86.1) − 45.4 = °C
The ProHeat display should read ±6 °F or ±3.3 °C.
OM-222 166 Page 16
4-13. Secondary Insulation Protection
Secondary insulation protection
circuitry automatically shuts down
the power source output if a
potentially hazardous condition
exists at the heating device
connected to the power source (e.g.
insulation has broken down on a
heating blanket causing the
conductor to come into contact with
the workpiece or a heating coil
touches the workpiece causing a
short in the output circuit).
The supplied ground lead(s) must
be connected between the
workpiece and power source to
provide proper secondary insulation protection from a short in the
output circuit.
For single output, only one
ground lead is required. For dual
output , use both ground leads.
1
2
Receptacles
Plug
To connect plug, align key with keyway, insert end into receptacle, and
rotate plug until tight.
3
4
Handle
Magnet
. The secondary isolation magnet
must be in contact with bare
metal (free from rust, paint,
grease, etc.).
5
Workpiece
Use handle to place magnet on the
workpiece.
1
2
3
5
4
803 994-B / Ref. 801 826-C / Ref. 801 828-C
OM-222 166 Page 17
4-14. 115 Volt AC Duplex Receptacle And Supplementary Protector
1
2
115 VAC 2.5 A Single-Phase
AC Receptacle RC1
Supplementary Protector CB1
(2.5 A)
The receptacle supplies nominal 115
volts ac auxiliary power for use with
the optional digital recorder. Maximum output from receptacle is 2.5
amperes.
1
2
1
CB1 protects 115 volt receptacle
RC1 from overload. If CB1 opens,
RC1 does not work.
2
803 993-C
4-15. Locating Thermocouples
Thermocouple location is one of the most critical steps in the Heat Treatment Operation.
Thermocouples shall be located as follows to provide a survey of heating uniformly and enable time and temperature control:
1.
Locate thermocouples to ensure that the full area of the heat band is monitored.
S
The code normally specifies the number of thermocouples to be used based on the pipe diameter.
S
The control thermocouple is placed in the plane of the weld (center of the heat zone).
S The control thermocouple is placed at the top of the pipe in a standard pipe joint configuration. In other
applications, the thermocouple should be located in the hottest portion of the weldment to be stress relieved.
2.
Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due to heat convection or
conduction, and have additional thermocouples applied.
3.
Attach a spare thermocouple beside control thermocouples.
4.
Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces.
5.
Physically inspect all thermocouples for continuity and mark them by an identification number corresponding to the recorder channel.
6.
Match the drawings of the workpiece indicating the numerous thermocouple locations, controlling thermocouple locations, etc. to weld identification information.
7.
The system is equipped with 3-pin thermocouple connections at the front of the unit. Six thermocouples can be attached to the power source.
S The system is equipped with 3-pin connectors to accommodate shielded extension cables. The shielded
cables protect from electrical interference.
8.
Type K thermocouple wire has a positive and negative wire. The positive wire is marked as solid yellow or striped yellow. The connector screw
terminals are marked positive and negative. Be sure to attach the wire to the connector with proper polarity.
OM-222 166 Page 18
9.
The following describes the thermocouple routing from work to power source.
S
Type K thermocouple wire (two wire) is attached directly to the workpiece using a
Thermocouple Attachment Unit (see next section for information on attaching thermocouples).
S
The other end is fitted with a 2-pin type K connector.
S The 2-pin connector plugs into the 3-pin composite extension cable. The extension cable has a six-channel
block of 3-pin female connectors. The pin size locates the position of the 2-pin connector on the extension.
S
The extension cable contains six, 3-wire bundles of shielded cable.
S
The 3-pin male extension cable plugs into the 3-pin female connector on the front of the power source.
1
3
4
2
For temperature control mode, the power
source must have (as a minimum) one
thermocouple connected to receptacle
TC1. If multiple thermocouples are desired,
either use individual thermocouple plugs or
the thermocouple extension cable.
To connect thermocouples to the power
source, proceed as follows:
. Do NOT weld thermocouples to workpiece while thermocouple cable is connected to the power source.
Turn Off power source.
1
Power Source
2
Thermocouple Receptacles
3
Individual Thermocouple Extension
Cable
4
Multiple Thermocouple Extension
Cable
Align plug pin(s) with receptacle socket(s)
and push plug into receptacle.
804 320-A
OM-222 166 Page 19
4-16. Attaching Welded Thermocouples
. Do NOT weld thermocouples while connected to power source.
1.
Attach thermocouples using a portable Thermocouple Attachment Unit (TAU). This unit spot welds thermocouple wire directly to the
workpiece. This method of thermocouple attachment ensures accurate temperature measurement.
2.
Clean (file or grind) any loose scale or rust from the workpiece at the places where the wires will be attached.
3.
Clean the location for the lead magnet to minimize resistance. Place the magnet as near to the thermocouple positions as possible.
4.
Strip 1/4 inch of insulation from the thermocouple wires.
5.
Set the output variable control of the TAU to about eighty percent (80%).
6.
Grasp one of the stripped wires with the tip of the jaws of the application pliers.
. Don’t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit. This will cause
the thermocouple wire to fuse to the pliers, rather than the workpiece.
7.
Press the end of the wire to the workpiece at ninety degrees to the surface, and maintain a firm pressure. Make sure the Thermocouple Attachment Unit is charged and wait for the ready light to glow.
8.
Press discharge button, and the wire should weld to the workpiece. There will be a sharp crack and a slight arc flash.
9.
Repeat the process with the other wire, placing it approximately 1/4 inch away from the first wire. Attach a spare thermocouple, and support
both thermocouples approximately 18 inches back from the connection with a band or fiber tape.
10.
Carefully bend the wire over at right angles. This brings the thermocouple wires out along or parallel to the workpiece. It also tests the strength
of the weld. If the weld shows signs of breaking, remove the wire, restrip the end, and repeat the process.
Strap Or Tape
Thermocouple
Wires
804 322-A
OM-222 166 Page 20
4-17. Using Contact Thermocouples
The welded thermocouples discussed previously can be used for preheating or stress relieving. As an alternative, in preheating applications, a contact
temperature sensor* can be used. This eliminates the need to weld thermocouples and the sensor can be moved during the preheat process to check
temperatures at other locations on the joint.
. Removing the contact probe will display a short duration of heat drop on the temperature recorder, if used.
The contact temperature sensor can be plugged into the thermocouple extension cable or a Type K 25 ft. armored extension cable* can be used. One of
these extensions is required for each sensor.
In preheating applications, the thermocouple must be placed under the induction coil. Temperatures at the weld joint can be checked with temperature
sensitive crayons to verify the preheat temperature.
Welded thermocouples are normally used in stress relieving applications due to their accuracy.
*See product literature for item part number.
4-18. Placing Temperature Probe
1
Blanket
2
Temperature Probe
Place temperature probe between
blanket and metal material. The
probe must be in contact with the
material being heated. The tip of the
probe should be positioned in the
approximate center of the blanket
anywhere along the blanket length.
1
2
804 321-A
OM-222 166 Page 21
SECTION 5 − COMPONENTS AND CONTROLS
5-1. Controls
3
4
5 6
7 10
9
8
11
18
16
17
2
15
14
13
19
12
1
803 995-B
. When a control panel button is pushed
the yellow lamp lights to indicate activation.
1
Power Switch
Use switch to turn power source On and
Off.
LED lights to indicate a system limit condition.
7
Heat On LED
LED lights to indicate the power source output is energized.
8
Stop Button
14 Parameter Button
Use button to display real time power
source operating parameters.
15 Cooler Button
Use button to turn cooler On and Off.
Use button to stop a heating process.
16 Increase Button
Provides temperature display of thermocouples 1 through 4.
9
Use button to hold a heating process.
Use button to increase values in set-up
screen.
3
10 Run Button
17 Decrease Button
LEDs indicate which thermocouples (1−4)
are used to control the heating process.
Use button to run a heating process.
Use button to decrease value in program
screen.
4
Use button to move selection cursor in the
4 x 40 LCD display (item 18).
2
TC1−4 Temperature Display
Control Thermocouple LEDs
Temperature Units LEDs
LEDs indicate units for temperature measurements (°F or ° C).
5
Fault LED
LED lights to indicate a system fault condition.
6
Limit LED
OM-222 166 Page 22
Hold Button
11 Cursor Button
18 4 x 40 LCD Display
Use button to program the process control.
Displays programming, runs status, parameter, fault and limit conditions, and troubleshooting guide.
13 Run Status Button
19 Thermocouple Input Receptacles
Use button to display real time operating
status.
Use receptacles for type K thermocouple
inputs.
12 Program Button
SECTION 6 − SETUP AND OPERATION
6-1. Safety Equipment
1
Wear
the
operation:
2
following
during
1
Dry, Insulating Gloves
2
Safety Glasses With Side
Shields
DO NOT wear rings or watches
during operation.
sb3.1* 1/94
6-2. System Description
The ProHeat 35 Induction Heating Power Source is designed to function either as an air-cooled system or a liquid-cooled system. Depending on the
system type (either air-cooled or liquid-cooled), the power source is automatically configured to operate and provide an output appropriate for the type
of connected heating device.
A special identifier, embedded within the extension cable connector, provides the means for the power source to configure itself by recognizing the type
of extension cable(s) attached to its output connectors.
Designed to provide a single level of output (up to 35 kW), the ProHeat 35 power source has two panel mounted connectors that are connected in
parallel to the power source output. This design allows the system to operate with either a single output extension cable or two output extension cables.
If a single output extension cable is used, a protective plug (provided with the system) MUST be placed on the unused output connector or the system
will not operate. If two output extension cables are used, they both MUST be of the same type (either both air-cooled or both liquid-cooled) or the system
will not operate (in this case, the protective plug is not used). When two extension cables and heating devices are utilized on the system, the extension
cable lengths and heating devices MUST be identical (see Section 4-8).
The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal temperatures reach or exceed specific set limits (see Section 9).
6-3. Power Source/System Setup
To view the System Setup screen, simultaneously press the Parameters
kW
A
V
Hz
and Program
buttons and the following screen will appear
on the display:
System Setup Screen
Degree Units: >_F
Tolerance...: ±25
Input Type..: K TC
Power Output: 35 KW
SYSTEM SETUP
Backlight: Yes
Control Mode: Manual
System Lock: No
To change a setting:
S
Press the Cursor
S
Press Increase
button to move the cursor to the parameter to be changed
or Decrease
button to select desired set-up feature.
OM-222 166 Page 23
Possible selections:
Degree Units: °F / °C
Tolerance: ±5 to 99 in °F (±3 to 55 in °C)
Backlight: Yes / No
Input Type: K TC
Control Mode: Temp / Time / Manual
Power Output: 1 to 35
System Lock: Yes / No
Degree Units − press the Increase
or Decrease
buttons to select temperature units. Selection will
drive the °F / °C indicator LEDs.
S
The factory default is °F.
S
Changing from °F to °C will convert stored program values: ramp temperature, soak temperature, ramp rate,
and temperature tolerance.
Tolerance − press the Increase
S
button to select the desired temperature tolerance.
or Decrease
button to turn LCD display backlight On or Off.
The factory default is ±25 °F.
Backlight − press the Increase
S
or Decrease
The factory default is On.
Input Type − press the Increase
or Decrease
button to select the desired temperature input
device.
S
The factory default and only selection is K TC.
Control Mode − press the Increase
or Decrease
button to select the desired method of system
control, either Temperature or Manual. For more details about methods of control, see Section
6-4.
S
The factory default is temperature based control.
Power Output − press the Increase
or Decrease
button to adjust the maximum power source
output.
S
The factory default is 35 kW.
System Lock − press the Increase
or Decrease
button to lock or unlock the operator interface to
prevent tampering with any programs. Yes indicates the system is locked, and No indicates the
system is unlocked.
S
The factory default is No (unlocked).
. All parameters in System Setup are considered global, and any changes to the system set-up parameters will apply to all programs.
OM-222 166 Page 24
To reset the system back to factory default settings, turn off the power source, and wait until the display goes blank. Turn on the power source. When
the display lights, press and hold the Increase
defaults. Release the Increase
and Decrease
and Decrease
buttons. A message will display Press Program to reset factory
buttons, and press the Program
button.
6-4. Programming
Programming allows the operator to setup a program for a particular heating process. The selections available are either Temperature control or Manual
control.
6-4-1.
Temperature-Based Control
Temperature-based control operates the system and controls the heating process based on temperature feedback from thermocouple inputs. Thermocouples must be used for this mode of operation or the system will not operate. Within the temperature-based mode there are four different
processes available as follows: Preheat, Bakeout, PWHT (Post-Weld Heat Treat), and Custom Program.
Press the Program button to access the programming mode. Use the cursor button to move the cursor to the desired temperature-based process,
then press the Program button again to select the process.
6-4-1-1. Preheat
The preheat process is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time.
When this process is selected, the following screen will appear on the LCD display:
Preheat Screen
Mode.......: Preheat
Control TC.: 1
Temperature: 400
Soak Time..: 01:00:00
The default position of the cursor is next to Control TC. Press the Increase
or Decrease
button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor
Decrease
button to move the cursor to the desired selection (Temperature or Soak Time), and press the Increase
or
button to change the value to the desired setting.
. The minimum and maximum temperature settings for preheat are 0 and 1000
F (−18 and 538 C). The minimum and maximum soak times are
0 and 100 hours. When the system is utilizing air-cooled blankets, the maximum temperature setting is 400 F (204 C). If the program setting
is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is pressed:
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
OM-222 166 Page 25
6-4-1-2. Bake-Out
The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from bake-out if desired. When this
process is selected, the following screen appears on the display:
Bake-Out Screen
Mode......: Bake−Out
Control TC:>1
Soak Temp.:
600
Soak Time: 01:00:00
Cool Temp.:
200
Cool Rate:
The default position of the cursor is next to Control TC. Press the Increase
600 _/Hr
or Decrease
button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor
press the Increase
button to move the cursor to the desired selection (Soak Temperature, Soak Time, Cool Temperature, or Cool Rate), and
or Decrease
button to change the value to the desired setting.
. The minimum and maximum soak temperature settings for bake-out are 0 and 1000 F(−18 and 538
C). The minimum and maximum soak times
are 0 and 100 hours. The minimum and maximum cool rates are 10 and 9999 /hr. When the system is utilizing air-cooled blankets, the maximum
temperature setting is 400 F(204 C). If the program setting is above 400 F (204 C), the following screen will appear on the LCD display when
the Run button is pressed:
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
6-4-1-3. PWHT (Post-Weld Heat Treat)
The post-weld heat treat process allows the operator to program a post-weld heat treat where ramp temperature (on increase and decrease) and
ramp rates are the same. When this process is selected, the following screen appears on the display:
PWHT Screen
Mode......: PWHT
Control TC:>1,2
OM-222 166 Page 26
600 _/Hr
Ramp Temp.:
200
Ramp Rate:
Soak Temp.:
400
Soak Time: 01:00:00
The default position of the cursor is next to Control TC. Press the Increase
or Decrease
button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor
button to move the cursor to the desired selection (Ramp Temperature, Ramp Rate, Soak Temperature, or Soak Time),
and press the Increase
or Decrease
Soak Temp
button to change the value to the desired setting.
Soak Time
Ramp Rate
Ramp Temp
Figure 6-1. Soak Parameters
. The minimum and maximum ramp temperature settings for PWHT are 0 and 1450 F (−18 and 788 C). The minimum and maximum ramp rates
are 10 and 9999 F/hr (6 and 5555 C/hr). The minimum and maximum soak temperatures are 0 and 1450 F (−18 and 788 C). The minimum
and maximum soak times are 0 and 100 hours. When the system is utilizing air-cooled blankets, the maximum temperature setting is 400 F (204
C). If the program setting is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is pressed.
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
6-4-1-4. Custom Program
In Custom Program, the operator can create a custom program with multiple steps or nonsymmetrical heat treat programs where the heating and
cooling rates and temperatures are different. When this process is selected, the following screen appears on the display:
. This is the screen for initial use of the system. Subsequent use of custom program will revert to the last program used.
OM-222 166 Page 27
Custom Program Screen
Mode.......: Custom Program
Segment....:
1
Type.......: End
Control TC.: 1
The default position of the cursor is next to Segment. Press the Increase
or Decrease
button to increase or decrease the
segment number, unless the segment type is End. In this case, the segment number will advance to segment 1.
Use the Cursor
button to move the cursor to the desired selection (Type or Control TC), and press the Increase
or Decrease
button to change the value to the desired setting. When the cursor is moved to the Type selection, pressing the Increase
Decrease
or
button changes the segment type to Step, Ramp, Soak, or End. The functions of each segment type are as follows:
S
Step increases the temperature in the part at full-programmed power. A maximum temperature of 1450° F
(788° C) can be programmed.
S
Ramp increases or decreases the temperature in the part at a controlled rate in degrees per hour. A
maximum temperature of 1450° F (788° C) and a maximum rate of 9999° F/hr (5555° C/hr) can be
programmed.
S
Soak will hold the temperature for a programmed time. A maximum hold (soak) time of 99:59
(hours:minutes) can be programmed.
S
End is programmed to indicate the completion of the cycle and termination of output power.
Step Function
When type is set to Step, the following screen appears on the display:
Custom Program Screen
Mode.......: Custom Program
Segment....:
1
Type.......:>Step
Temperature:
Use the Cursor
or Decrease
Pressing the Cursor
600
button to move the cursor to the Temperature position and the initial temperature can be adjusted using the Increase
button.
button again automatically advances the program to the next segment number.
Ramp Function
When type is set to Ramp, the following screen appears on the display:
OM-222 166 Page 28
Custom Program Screen
Mode.......: Custom Program
Segment....:
1
Type.......: Ramp
Temperature:
Use the Cursor
600
Ramp Rate:
600 _/Hr
button to move the cursor to the Temperature or Ramp Rate position and use the Increase
or Decrease
button to set the desired value.
When the cursor is in the Ramp Rate position, pressing the Cursor
button again automatically advances the program to the next segment
number.
Notes
OM-222 166 Page 29
Soak Function
When type is set to Soak, the following screen appears on the display:
Custom Program Screen
Mode.......: Custom Program
Segment....:
1
Type.......:>Soak
Soak Time..: 00:01:00
Use the Cursor
button to move the cursor to the Soak Time position and use the Increase
or Decrease
button to set
the desired value.
When the cursor is in the Soak Time position, pressing the Cursor
button again automatically advances the program to the next segment
number.
End Function
When type is set to End, the following screen appears on the display:
Custom Program Screen
Mode.......: Custom Program
Segment....:> 2
Type.......: End
Control TC.: 1
The only changeable parameter in the End segment is selecting the number of thermocouples. Use the Cursor
to the Control TC position. Press the Increase
or Decrease
button to move the cursor
button to select the number of control thermocouples to be used for
the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2 thru TC4 can be used for
controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display illuminates.
A custom program can contain up to 10 segments. To view Program parameters, position the cursor at segment and use the Increase
Decrease
button to advance through the segment numbers until the End segment. When a segment number is changed, appropriate
segment parameter information appears on the display.
OM-222 166 Page 30
or
Typical 5-Segment Custom Program
Custom Program Screen
Mode.......: Custom Program
Segment....:
1
Type.......:>Step
Temperature:
600
Temperature increases to 600 degrees at full-programmed power.
Custom Program Screen
Mode.......: Custom Program
Segment....:
2
Type.......: Ramp
Temperature:>1250
Ramp Rate:
600 _/Hr
Controlled heating to 1250 degrees F at a ramp of 600 degrees per hour.
Custom Program Screen
Mode.......: Custom Program
Segment....:
3
Type.......: Soak
Soak Time..:>01:00:00
Soak at 1250 degrees F for a period of 1:00.
Custom Program Screen
Mode.......: Custom Program
Segment....:
4
Type.......:>Ramp
Temperature:
600
Ramp Rate:
600 _/Hr
Controlled cooling to 600 degrees F at a rate of 600 degrees per hour.
Custom Program Screen
Mode.......: Custom Program
Segment....:
5
Type.......: End
Control TC.: 1
End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.
6-4-2.
Manual Control
Manual control allows programming of a specific power level for a specific period of time. When this process is selected, the following screen appears
on the display:
OM-222 166 Page 31
Manual Program Screen
Mode....: Manual
Power..:
0.0 KW
Command.:
Current:
0 A
Voltage:
0 V
0.0 KW
Run Time: 00:03:00
Frequency:
4.5 KHz
The only programmable selections are Command power and Run Time. Command can be adjusted to deliver up to 35 KW (based on maximum
power selected in the set-up screen) for a period of up to 99 hours, 59 minutes, 59 seconds.
Power source operating power, current, voltage, and frequency are shown on the right-hand side of the display.
To reset the system back to factory default settings, turn off the power source, and wait until the display goes blank. Turn on the power source. When
the display lights, press and hold the Increase
defaults. Release the Increase
and Decrease
and Decrease
buttons. A message will display Press Program to reset factory
buttons, and press the Program
button.
6-5. Run Status
Run status allows the operator to check status of a program during in-process heating. Depending on the control mode (Temperature or Manual) and
the temperature based mode (Preheat, Bake-Out, PWHT, or Custom), different style screens appear on the display. Run status is for monitoring
purposes only and has no selectable or changeable parameters.
6-5-1.
Temperature Based Control
6-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen
Run Status Screen
Mode.......: Preheat
TC5:
77
Target Temp: −−−−
TC6:
77
Countdown..: −−:−−:−−
Status.....: Stopped
Mode displays the programming mode (Preheat, Bake-Out, PWHT, or Custom Program). During active operation, Target Temp shows the target
temperature based on the specific program, Countdown shows the time remaining in a soak segment, and Status shows the program segment type
(step, soak, ramp, hold, or stopped). TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.
6-5-1-2. Custom Program
Run Status Screen
Mode.......: Custom Program
TC5:
77
Target Temp: −−−−
TC6:
77
Countdown..: −−:−−:−−
Segment:
1
Status.....: Stopped
During active operation, Target Temp shows the target temperature based on the active segment, Countdown shows the time remaining in a soak
segment, and Status shows the program segment type (step, soak, ramp, hold, or stopped) of the active segment and the active segment number.
TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.
OM-222 166 Page 32
6-5-2.
Manual Control
Run Status Screen
Mode.....: Manual
TC5:
77
Power....:
TC6:
77
0.0 KW
Countdown: −−:−−:−−
Status...: Stopped
During active operation, Power shows the actual power delivered from the power source, Countdown shows the time remaining in the heating cycle,
and Status indicates if the system is running or stopped. TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for
monitoring purposes only.
. No changes can be made to the run status screen, and the Cursor, Increase and Decrease buttons are not functional.
6-6. Parameters
During active operation, the Parameters screen allows the operator to monitor the power source output operating parameters. These parameters include output power, output amperage, output voltage, and output frequency. In addition, temperatures of thermocouples TC5 and TC6 are also
displayed. The Parameters screen is for monitoring purposes only and has no selectable or changeable parameters.
Parameters Screen
Power....:
0.0 KW
TC5:
77
Current..:
0 A
TC6:
77
Voltage..:
0 V
Frequency:
4.5 KHz
6-7. Cooler
The Cooler
button is used to turn the cooler On or Off on systems using liquid-cooled output cables. Systems using liquid-cooled output
cables will not deliver output unless the cooler is On. If the cooler is not started prior to initiating a heating cycle, the system will automatically start the
cooler when the Run
by pressing the Cooler
button is pressed. Pressing the Stop
button does not shut off the cooler. The cooler must be shut off separately
button.
When power source output is energized, the cooler cannot be turned off. If the Cooler
button is pressed while output is energized, the follow-
ing screen will appear on the display:
Cooler Message Screen
Cooler cannot be turned off
while output is on
OM-222 166 Page 33
. The Cooler button is inactive when no cooler is detected and no liquid-cooled output cable is attached.
6-8. Real-Time Operation
Each time the unit is first turned On it initiates a system check routine that includes verification of communication between circuit boards and checking
for output isolation faults. During this check routine, all displays and LEDs illuminate and the following screen appears on the display:
Power Up Message Screen
ProHeat
Firmware Revision X.XX
Copyright (c) 2005
Miller Electric Mfg. Co.
X.XX indicates the firmware revision number installed in the unit.
If an error is detected during the check routine, the system fault LED illuminates and an error message screen appears on the display (see Section 9-5).
When the check routine is completed successfully, the operator interface defaults to the following:
S
The Stop
button indicator LED illuminates to indicate no heating cycle is in process.
S
The temperature displays indicate actual temperature from the TC’s (thermocouples). If no thermocouples
are connected, the displays indicate OPEN.
S
Control LEDs illuminate to indicate the number of control TC’s in the last program.
S
The appropriate degree units (°F or °C) light illuminates.
S
The display defaults to the Run Status screen from the last program used and the Run Status
button indicator LED illuminates.
S
If no fault or limit conditions are present, system status lights are not illuminated.
Once set up is complete for the desired program procedure (see Section 6-3), pressing the Run
program run is initiated, the Run
button will initiate a heating cycle. When a
button yellow indicator LED illuminates and the Heat On blue indicator LED illuminates to indicate output is
present to the coil. The cycle will continue until the end of the program is reached or the Stop
button is pressed.
The system has a hold function that will maintain a temperature or hold the soak time of any active temperature controlled program. Pressing the Hold
button will only activate the hold function while in the run mode. If the system is not in the run mode, the following screen will appear on the
display:
Hold Message Screen
Must be running to enter Hold mode
OM-222 166 Page 34
In addition, when running in Manual operating mode, the Hold
pressing the Hold
button is not functional. If the system is running in Manual operating mode,
button will cause the following screen to appear on the display:
Hold Message Screen
Hold mode not available when
temperature control is not active
Pressing the Hold
button will activate the hold function while running a temperature controlled program. While in the hold mode, the parame-
ters for the program in process can be modified. The cycle will continue after pressing the Run
button. A change of program parameters
during the hold will not change the original program. The original program parameters are maintained for the next heating cycle.
To make changes to a program while in run mode, press the Hold
button and the yellow indicator LED will illuminate, and the Run
button yellow indicator LED will turn off. When in hold, the system will maintain the actual temperature of the hottest thermocouple while the program is
being changed.
S
Press the Program
button and the yellow indicator LED will illuminate. The display will change to
show the current mode of operation or the current segment of a Custom Program.
S
Use the Cursor
S
Press the Increase
S
Press the Run
the Hold
button to move the cursor to the parameter that will be changed.
or Decrease
button to make desired changes.
button to resume program operation and the yellow indicator LED will illuminate, and
button yellow indicator LED will turn off.
Any program parameter (temperatures, rates, times, or number of TC’s) can be changed while in hold. In a custom based program, any segment number can be changed; however, if the operation of a segment has already been completed in a program, the change to that segment will not affect the
program function.
S
Press the Stop
button to end the program.
OM-222 166 Page 35
6-9. System Operating Characteristics
The power source delivers a high-frequency alternating current output that energizes the coil creating the magnetic field used to heat the workpiece.
The power source output characteristics are a function of the configuration, type and number of coils used as shown in the following table:
Table 6-1. Power Source Output Characteristics
Output Type
Air Cooled Single and Dual
Single Liquid Cooled
Dual Liquid Cooled
Maximum Amperage
Maximum Voltage
Frequency Range
250 A per output for 15 minutes.
After 15 minutes, power steps
down to limit current to 150 amperes per output for continuous
operation.
700 V
5 − 25.7 kHz
See Note 1
700 V
25.7 − 30 kHz
350 A
700 V
5 − 20 kHz
See Note 2
700 V
20 − 30 kHz
350 A per output/700 A total
700 V
5 − 20 kHz
See Note 2
700 V
20 − 30 kHz
300
. Note 1: In the frequency range
Air Cooled Output
of 25.7 to 30 KHz, the maximum output amperage decreases linearly from 250 down
to 175 amperes per output. Regardless of frequency, after 15
minutes the maximum output is
reduced to 150 amperes per
output.
Max Amperage Per Output
250
200
150
100
50
0
5
400
25.7
Frequency (KHz)
30
. Note 2:
In the frequency range
of 20 to 30 KHz, the maximum
output decreases linearly from
350 down to 175 amperes per
output.
Liquid Cooled Output
Max Amperage Per Output
350
300
250
200
150
100
50
0
OM-222 166 Page 36
5
Frequency (KHz)
20
30
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
2
l Damaged or Unreadable
Labels
2
1
~ Output Connector Contacts
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
2
Reference
Section 4-8,
4-13
1
~ Ground Sense Lead Receptacles
~ Operator Interface Overlay
1
n Integrity Of Protective
Plug, Replace If Necessary
Every
6
Months
nlCracked Cables
Section 9-8
~ Inside Unit
Every
Year
Sections
7-2, 7-3
n Verify Unit Calibration
OM-222 166 Page 37
7-2. Calibration Verification Equipment
1
2
3
1 Thermocoupler Calibrator
Suggested calibrator from Fluke item 714
or equivalent.
2 Type K Mini Connector
Suggested connector from Fluke item
80CK−M or equivalent.
A length of type K thermocouple wire is
required. Connect red to negative and
5
4
yellow to positive when wiring connectors.
3 Type K 2-Pin Male Connector
Suggested connector from Newport item
OST−K−M or equivalent
4 Calibration Label
Suggested label from Q−CEES item
QCC306BU or equivalent.
5 Precision Digital Voltmeter (DVM)
6
Suggested meters are Agilent Multimeter
or Hewlett Packard Multimeter Model
34401A or equivalent. DVM must be able
to read to three decimal places (0.000).
6
Interconnecting Cable
MILLER Part No. 300168 can be used to
connect the Recorder to the DC power
supply.
7-3. Calibration Verification Procedure
Calibration verification should be done every year. Use appropriate Certificate of Calibration to record calibration information. A spreadsheet could also
be used to record the information.
7-3-1.
Initial Set Up
1.
Power switch off
2.
Have qualified person connect primary power to ProHeat 35.
3.
Turn ProHeat 35 power switch on.
4.
Press and hold the Program button, then press Parameters to enter setup mode.
5.
Press Cursor button 4 times to get to Control Mode line.
6.
Press the Decrease button to change to Manual, if necessary.
7.
Press the Run Status button. (TC5 and TC6 will show in upper right-hand corner of display)
8.
Let unit idle for a minimum of 15 minutes before checking calibration.
9.
Turn on Fluke 714 Thermocouple Calibrator and Precision DVM. Leave them on for a minimum of 15 minutes before checking calibration.
7-3-2.
TC Input/Output Check
1.
Connect precision DVM (DC Volts set to display in thousandths) to RC9. This is the top connector located on the back of the ProHeat 35. Red
lead to pin 1 and black to pin 5.
2.
Set TC calibrator to 382.0 °F or 194.5 °C. Connect to TC1 input jack on front of ProHeat.
3.
Verify TC display value of (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F) or (±3.3°C). DVM reads 2.787 Vdc (±0.038) (2.749 – 2.825).
4.
Enter DVM values into calibration certificate If you are creating your own spreadsheet use the following calculation.
The voltage to temperature calculation is:
(DC Volts Out x 155) − 50 = °F
(DC Volts Out x 86.1) − 45.4 = °C
5.
Repeat steps 1.−4. for TC2 – TC6 input jacks.
For TC2 move red precision DVM lead to RC9 pin 2.
For TC3 move red precision DVM lead to RC9 pin 3.
For TC4 move red precision DVM lead to RC9 pin 4.
For TC5 move red precision DVM lead to RC9 pin 6.
For TC6 move red precision DVM lead to RC9 pin 7.
Note: TC5 and TC6 will show in upper right-hand corner of display.
6.
Repeat steps 1.−5. with TC calibrator set to 882.0 °F or 472.2 °C, verify TC display value (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F)
or (±3.3°C). DVM reads 6.013 Vdc (±0.038) (5.975 – 6.041).
7.
Repeat steps 1.−5. with TC calibrator set to 1382.0 °F or 750 °C, verify TC display value (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F)
or (±3.3°C). DVM reads 9.239 Vdc (±0.038) (9.201 – 9.277).
7-3-3.
1.
Finishing Procedure
If ProHeat 35 was set for Temp in Control Mode follow steps 7-3-1, steps 4.−6. to change it back to Temp.
OM-222 166 Page 38
2.
Turn ProHeat 35 power switch off.
3.
Have qualified person disconnect primary power.
4.
Remove precision DVM and TC calibrator.
5.
Complete calibration label & place it on unit directly above TC1 display.
I.D. No. (TC board serial number) Be sure the serial number matches the board in the machine.
By (your initials) Date (today’s date)
Due (date 1 year from today)
6.
Print a copy of the certificate to send with the ProHeat 35.
7.
If entering data in a spreadsheet, save data.
Notes
OM-222 166 Page 39
OM-222 166 Page 40
Calibration Date:
Re−Calibration Date:
A−232171−B 09/09/08
Calibrated Multimeter:
Thermocouple Calibrator:
Instrumentation Used:
CHANNEL
CHANNEL
CHANNEL
CHANNEL
CHANNEL
CHANNEL
1
2
3
4
5
6
PRIMARY STANDARD
382 (°F)
Voltage
Equivalent
Out (V)
Temp (°F)
PRIMARY STANDARD
1382 (°F)
Voltage
Equivalent
Out (V)
Temp (°F)
Serial Number:
Serial Number:
PRIMARY STANDARD
882 (°F)
Voltage
Equivalent
Out (V)
Temp (°F)
Company name
does hereby certify the above instrument was calibrated against standards
maintained by Company name
and meets or exceeds all published specifications.
The accuracy of these standards is directly traceable to the National Institute of Standards and Technology.
TCI Serial Number:
Certified by:
CERTIFICATE OF CALIBRATION
Com pany Nam e
Street
PO Box
City, State, Zip Code
OM-222 166 Page 41
Calibration Date:
Re−Calibration Date:
A−232171−B 09/09/08
Calibrated Multimeter:
Thermocouple Calibrator:
Instrumentation Used:
C H AN N E L
C H AN N E L
C H AN N E L
C H AN N E L
C H AN N E L
C H AN N E L
1
2
3
4
5
6
P R IM AR Y S T AN D AR D
1 94 (°C )
V o lta g e
E q u iv a le n t
O u t (V )
T em p (°C )
P R IM AR Y S T AN D AR D
75 0 (°C )
V o ltag e
E q u iva len t
O u t (V )
T e m p (°C )
Serial Number:
Serial Number:
P R IM AR Y S T AN D AR D
4 7 2 (°C )
V o ltag e
E q u iv a le n t
O u t (V )
T e m p (°C )
Company name
does hereby certify the above instrument was calibrated against standards
maintained by Company name
and meets or exceeds all published specifications.
The accuracy of these standards is directly traceable to the National Institute of Standards and Technology.
TCI Serial Number:
Certified by:
CERTIFICATE OF CALIBRATION
Com pany Nam e
Street
PO Box
City, State, Zip Code
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-222 166 Page 42
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.
8-1. Symbol Usage
OM-222166J - 2007−06, safety_ihtm 2007−04
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 explained 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 symbols and related instructions below for necessary actions to avoid the
hazards.
8-2. Servicing 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.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off induction heating power source and
disconnect and lockout input power using line
disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving an induction heating power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section before touching any parts.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Do not touch or handle induction head/coil
during operation.
D Keep metal jewelry and other metal personal
items away from head/coil during operation.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
EXPLODING PARTS can cause injury.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off induction heating power source before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OM-222 166 Page 43
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before using induction heating equipment again.
D Do not block or filter airflow to unit.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for induction heating safety precautions.
D Use only genuine replacement parts from the
manufacturer.
8-3. California Proposition 65 Warnings
Welding 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 lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive 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 reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
8-4. EMF Information
Considerations About Induction Heating And The Effects Of Low Frequency Electric And Magnetic Fields
Induction heating current, as it flows through induction heating cables,
will cause electromagnetic fields. There has been and still is some
concern about such fields. However, after examining more than 500
studies spanning 17 years of research, a special blue ribbon committee
of the National Research Council concluded that: “The body of
evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a humanhealth hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when using induction heating equipment.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
OM-222 166 Page 44
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep induction heating power source and cables as far away
from operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 9 − DIAGNOSTICS & TROUBLESHOOTING
The ProHeat 35 power source has on-board capabilities to aid in troubleshooting problems should any conditions occur during operation. This
troubleshooting capability consists of the Fault LED, Limit LED, and message screens that appear on the front panel LCD display.
9-1. Operator Interface Indicators
1
2
3
803 995-B
1
Fault LED
LED lights to indicate a system fault
condition.
2
Limit LED
LED lights to indicate a system limit
condition.
3
4 x 40 LCD Display
Displays programming, run status, parameters, fault and limit conditions, and
troubleshooting guide.
OM-222 166 Page 45
9-2. Limit Conditions
A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its optimum operating conditions or
parameters. Should a limit condition occur during operation, the yellow Limit LED will flash to indicate a problem. If the active screen on the LCD display
is Run Status or Parameters, a message describing the particular limit condition will appear on the display. If the active screen is Program, press the
Run Status
button to display the limit condition.
In a limit condition, the power source will continue to deliver output power and protect itself from damage by reducing the output power. This situation
allows the operator time to determine the best action to correct the problem as described by the limit message on the LCD display.
If a limit condition occurs, there are two selectable options:
S
Acknowledge the limit and continue operation.
S
Terminate operation to correct the problem causing the limit.
button will acknowledge the limit and continue operation with the existing set up. In the acknowledge state, the yellow
Pressing the Decrease
Limit LED will stop flashing and remain on continuously. The LCD display will revert to an active screen once the Program
button, or Parameters
kW
A
V
Hz
button, Run Status
button is pressed.
If a new limit condition should occur after the first is acknowledged, the yellow Limit LED will start flashing to indicate a new problem. To display the limit
condition, press the Run Status
button and the LCD display will show a message describing the new and previous limit messages.
To obtain additional information regarding the limit condition and suggested solutions to resolve the limit, press the Increase
button, and the
LCD display will indicate possible solutions based on the type of limit condition.
If the operator determines that the best course of action is to terminate operation and make suggested changes to the setup to eliminate the limit condition, press the Stop
button. After changes are made to the setup, press the Run
button to restart the process.
9-3. Limit Condition Codes
Limit Condition
Additional Information
L01: Thermocouple #1 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L02: Themocouple #2 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L03: Thermocouple #3 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L04: Thermocouple #4 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L05: Thermocouple #5 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L06: Thermocouple #6 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L07: Output Voltage Limit
Tighten blanket against pipe surface
L08: Output Voltage Limit
Increase number of turns
Increase coil space
Shorten extension cable
Increase insulation width
L09: Output Current Limit
Tighten blanket against pipe surface
L10: Output Current Limit
Increase number of turns
Decrease coil space
Tighten cable on insulation
OM-222 166 Page 46
Limit Condition
Additional Information
L11: Coolant Overtemp Limit
Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
L12: Power Source Overtemp Limit
Check for blocked vents
Clean wind tunnel heat sinks
L13:Cable Connection
Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
9-4. Fault Conditions
A fault condition occurs if the system encounters an isolation fault, encounters operating conditions outside operational limits, or if there is a serious
problem with the system. Should a fault condition occur, the output is immediately turned off, the red Fault LED flashes and the Stop
button
LED flashes. If the active screen on the LCD display is Run Status or Parameters, a message describing the particular fault condition will appear on the
display. If the active screen is Program, press the Run Status
Pressing the Decrease
Stop
button to display the fault condition.
button will acknowledge the fault and the red Fault LED will stop flashing and remain on continuously. However, the
button LED will continue to flash indicating that the process has stopped.
To obtain additional information regarding the fault condition and suggested solutions to resolve the fault, press the Increase
button, and the
LCD display will indicate possible solutions based on the type of fault condition. In most cases, a fault condition will indicate that service is required.
9-5. Fault Condition Codes
Fault Condition
Additional Information
F51: Thermocouple #1 Internal Fault
Service required
F52: Themocouple #2 Internal Fault
Service required
F53: Thermocouple #3 Internal Fault
Service required
F54: Thermocouple #4 Internal Fault
Service required
F55: Thermocouple #5 Internal Fault
Service required
F56: Thermocouple #6 Internal Fault
Service required
F57: CJT Sensor Internal Fault
Service required
F58: Output Voltage Fault
Service required
F59: Output Current Fault
Service required
F60: Temperature Sensor Fault
Check control TC connections
Check control TC extension cable
F61: Coolant Flow Fault
Check for coolant leak
Clean for coolant blockage
Check coolant filter and level
Check coolant connections
F62: Isolation Fault
Check for exposed conductor
Clean for moisture on cables
F63:Line Voltage Fault
Check line voltage
F64: Power Source Overtemp Fault
Verify power source vents and
wind tunnel are unobstructed
F65: Current Source Fault
Service required
F66: Under Frequency Fault
Check for loose or open connections
in output cable
Decrease number of turns
Decrease coil space
OM-222 166 Page 47
Fault Condition
Additional Information
F67: Over Frequency Fault
Verify heating cable properly wrapped
Verify material being heated is magnetic
F68: Cable Connection Fault
Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
F69: Coolant Overtemp Fault
Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
F70: Internal Communication Fault
Service required
F71: Internal Thermistor Fault
Service required
F72: Coolant Thermistor Fault
Service required
F73: Decoupled/Open Coil
Service required
F74: Isolation Fault Self-Test Error
Service required
F75: Internal Power Supply Fault
Service required
F76: Current Source Control Fault
Service required
F77: Power Source Internal Comm Fault
Service required
F78:Output Current Sense Fault
Check for loose/open output connection or an extension cable connected with no coil attached
at the end.
9-6. System Diagnostic Screens
Additional system diagnostics are available and accessible through the operator interface. Detail operational parameters can be accessed by pressing
and holding the Run Status
button and pressing the Parameters
kW
A
V
Hz
button.
When this feature is initially activated, the following screen appears on the LCD display:
System Diagnostic Screen
RemCmd: 1023 Off
Cable1: LQD
OutI1:
0 A
Cable2: LQD
OutI2:
0 A
ClntFR: 0.75 GPM
IsrcFb:
0 A
ClrSts: Flowing
RemCmd − This is the value of the remote command and the status of the remote contactor.
. Remote controls can be used to enable/disable output. They do not affect output power level.
Out I1 − This is the value of the output current on output 1.
Out I2 − This is the value of the output current on output 2.
Isrc FB − This is the value of the amperage in the current source inverter.
Cable 1 − This is the cable type hooked up to output number one. Possible labels:
S
AIR − for an air-cooled cable
S
LQD − for a liquid-cooled cable
S
PLUG − for a protective plug
S
OPEN − no cable or plug in place
Cable 2 − This is the cable type hooked up to output number two. Possible labels:
S
AIR − for an air-cooled cable
S
LQD − for a liquid-cooled cable
S
PLUG − for a protective plug
OM-222 166 Page 48
DIAG1
S
OPEN − no cable or plug in place
ClntFR − This is the coolant flow rate (in GPM) from the cooler on a liquid-cooled system.
ClrSts − This is the status of the cooler. Possible labels:
S
Off
S
Flowing
The second diagnostic screen is available by again pressing and holding the Run Status
button and pressing the Parameters
kW
A
V
Hz
button.
System Diagnostic Screen
VLnA−B: 460V
Therm1:
75
DIAG2
VLnB−C: 460V
Therm2:
75
Therm5: OPEN
VLnC−A: 460V
Therm3:
75
ClrTmp:
VBus: 650V
Therm4: OPEN
77
RmtFlw: Off
VLnA-B − This is the phase to phase line voltage between phases A and B.
VLnB-C − This is the phase to phase line voltage between phases B and C.
VLnC-A − This is the phase to phase line voltage between phases C and A.
VBus − This is the DC bus voltage.
Therm1 − This is the temperature of the current source primary heatsink.
Therm2 − This is the temperature of the bridge heatsink.
Therm3 − This the the temperature of the current source secondary heatsink.
Therm4 − Open (not used).
Therm5 − Open (not used).
ClrTmp − This is the temperature of the coolant on a liquid-cooled system.
S
OPEN − no cooler is detected.
RmtFlw − This is the status of the relay contacts for remote coolant flow on a liquid-cooled system.
S
OFF
S
ON
. RmtFlw feature is unsupported on the current platform.
OM-222 166 Page 49
9-7. Removing Wrapper and Measuring Input Capacitor Voltage
!
900 Volts dc can be present
on the capacitor bus and
significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage on inverter assembly
as shown to be sure the input
capacitors have discharged
before working on unit.
!
Turn Off welding power
source, and disconnect
input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
Tools Needed:
5/16, 3/8 in
Remove right side panel and disconnect fan motor FM3.
1
Current Source Interconnect
Board PC4
2
Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC4 as shown until voltage drops to
near 0 (zero) volts.
. If the capacitor voltage does
not drop to near zero after
several minutes, use a bleeder
resistor of between 200 and
500 ohms, at least 10 watts,
and #16 AWG 600 volts ac insulation rated wire to discharge
the capacitor(s).
1
3
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit. Reconnect FM3 and reinstall right side
panel when finished.
+ lead to right bus terminal,
− lead to left bus terminal
3
Typical Bleeder Resistor
200 to 500 ohm, 10 watt
wire wound resistor
2
#16 AWG 600 Volts AC
Insulation Rating
804 519-B
OM-222 166 Page 50
9-8. Blowing Out Inside Of Unit
!
Turn Off welding power
source and disconnect input
power.
!
Remove wrapper and be
sure input capacitors are
discharged.
Blow out inside of unit. Blow out fan
motors in right side panel and front
panel.
804 625-B
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-222 166 Page 51
SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram
OM-222 166 Page 52
218 057-G
OM-222 166 Page 53
SECTION 11 − PARTS LIST
. Hardware is common and
3
5
not available unless listed.
4
11
See Figure
11-3
12
13
14
9
8
1
11
6
7
See Figure
11-2
10
2
Ref. 804 218-D
Figure 11-1. Wrappers
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Wrappers
. . . 1 . . . . . . . . . . . . +217 470
. . . 2 . . . . . . . . . . . . . 217 860
. . . 3 . . . . . . . . . . . . +217 325
. . . 4 . . . . . . . . . . . . . 147 876
. . . 5 . . . . . . . . . . . . . 217 334
. . . 6 . . . . . . . . . . . . . 217 468
. . . 7 . . . . . . . . . . . . . 218 280
. . . 8 . . . . . . . . . . . . . 222 106
. . . 9 . . . FM3 . . . . . 236 263
. . . 10 . . . . . . . . . . . . . 206 270
. . . 11 . . . . . . . . . . . . . 198 035
. . . 12 . . . . . . . . . . . . . 197 931
. . . 13 . . . . . . . . . . . . . 197 900
. . . 14 . . . . . . . . . . . . . 127 836
. . . . . . . . . RC2 . . . . . 135 635
. . . . . . . . PLG2 . . . . 131 054
. . . . . . . . PLG61 . . . 131 204
. . . . . . . . PLG63 . . . . 115 094
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock and input pwr (FR) . . . . . . . . . . . . . . . . . . .
COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning general precautionary induction heat . . . . . . . . . . . . . . . .
PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR, primary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HINGE, cont polyolefin copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN, muffin 24VDC 3000 RPM 130 CFM . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNET, permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, work ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUG, tw lk insul male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 54
1
. Hardware is common and
5
4
not available unless listed.
8
11
3
13
12
2
6
7
10
9
804 219-A
Figure 11-2. Front Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Front Panel
. . . 1 . . . . . . . . . . . . . 217 323
. . . 2 . . . . . . . . . . . . . 216 225
. . . 3 . . . . . . . . . . . . . 216 224
. . . 4 . TC1−TC6 . . 218 686
. . . 5 . . . . . . . . . . . . . 217 327
. . . 6 . . . . S1 . . . . . 213 060
. . . 7 . . . . . . . . . . . . . 212 810
. . . 8 . . . . . . . . . . . . . 221 493
. . . 9 . . . . . . . . . . . . . . 115 440
. . . 10 . . . . . . . . . . . . . 224 143
. . . 11 . . . PC8 . . . . . 216 068
. . . 12 . . . PC2 . . . . . 216 072
. . . 13 . . . . . . . . . . . . . 148 297
. . . . . . . . PLG24 . . . . 115 091
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, ProHeat 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE ASSY, thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, TC receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, tgl 3pst 60 A 600 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, on−off w/symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, TC 1−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDOFF, no 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, 006−32 .31 hex .20 stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
6
1
1
1
1
14
1
1
1
2
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 55
. Hardware is common and
12
not available unless listed.
5
13
10
9
14
1
7
2
4
6
3
8
804 220-A
11
Item
No.
Dia.
Mkgs.
Figure 11-3. Rear Panel
Part
No.
Description
Quantity
Figure 11-3. Rear Panel
. . . 1 . . . . . . . . . . . . . 217 324
. . . 2 . . . RC1 . . . . . 174 207
. . . 3 . . . . . . . . . . . . . 127 837
. . . 4 . . . CB1 . . . . . 089 807
. . . 5 . . . . . . . . . . . . . 220 824
. . . 6 . . . . . . . . . . . . +218 689
. . . 7 . . . . . . . . . . . . . 602 498
. . . 8 . . . . . . . . . . . . . 010 467
. . . 9 . . RC14 . . . . 143 976
. . . 10 . . . RC9 . . . . . 047 636
. . . 11 . . . . . . . . . . . . . 224 989
. . . . . . . . . . . . . . . . . . . 234 531
. . . 12 . . . . . . . . . . . . . 224 042
. . . 13 . . . . . . . . . . . . . 170 391
. . . 14 . . . . . . . . . . . . . 147 195
. . . . . . . RC21,22 . . . 135 635
. . . . . . PLG21,22 . . 131 054
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, str dx grd 2P 3W 15 A 125 V . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, tw lk insul fem (dinse type) . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTARY PROTECTOR, man reset 1P 2.5 A 250 VAC . . . . . .
COVER, receptacle weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, danger high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+PINS,(service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE ASSY, output (with leads) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHELL, w/contact pin and socket (service kit for 224 989) . . . . . . . . . . . .
CONNECTOR, circ CPC protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, circ MS protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, 375−27 .54 hex .25 H nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
2
0
1
1
1
2
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 56
. Hardware is common and
14
not available unless listed.
1
4
14
12
3
6
2
5
10
13
3
7
6
9
16
15
8
Figure 11-4. Base w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
804 221-D
Quantity
Figure 11-4. Base w/Components
. . . 1 . . . . . . . . . . . . . 217 328
. . . 2 . . . . . . . . . . . . . 213 865
. . . 3 . . . . . . . . . . . . . 213 939
. . . 4 . . L1,L2 . . . . 218 692
. . . 5 . . . . . . . . . . . . . 216 815
. . . 6 . . . C1,2 . . . . 213 870
. . . 7 . . . . T1 . . . . . 213 583
. . . 7 . . . . T1 . . . . . 227 065
. . . 8 . . . . . . . . . . . . . 216 629
. . . 9 . FM1,FM2 . . 222 728
. . . 10 . . . RC4 . . . . . . 115 090
. . . 11 . . . . . . . . . . . . . 217 992
. . . 12 . . . . . . . . . . . . . 224 973
. . . 13 . . . . . . . . . . . . . . 603 115
. . . 14 . . . . . . . . . . . . . 026 627
. . . . . . . . PLG4 . . . . . 115 094
. . . 15 . . . . . . . . . . . . . 226 837
. . . 16 . . . . . . . . . . . . . 226 838
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
FRAME, lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock can kill significant . . . . . . . . . . . . . . . . . . . .
INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, cap support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, hf (400V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN, nuffin 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, air bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, lift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEATHERSTRIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, rubber .343 id x .875 od x .093 thk . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
2
1
1
1
2
1
1
2
2
1
1
2
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 57
. Hardware is common and
See Figure 11-6
not available unless listed.
9
11
10
3
13
1
7
12
8
16
5
6
14
15
4
2
Figure 11-5. Top Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
804 222-A
Quantity
Figure 11-5. Top Windtunnel
. . . 1 . . . . . . . . . . . . . 218 424
. . . 2 . . . . . . . . . . . . . 218 684
. . . 3 . . . . . . . . . . . . . 025 248
. . . 4 . . . RT2 . . . . . 222 327
. . . 5 . . . . . . . . . . . . . 083 147
. . . 6 . . . . . . . . . . . . . 605 339
. . . 7 . . . . . . . . . . . . . 098 691
. . . 8 . . . . . . . . . . . . . 217 326
. . . 9 . . . . . . . . . . . . . 218 691
. . . . . . . . . . . . . . . . . . . 229 382
. . . 10 . . . PC5 . . . . . 225 556
. . . 11 . . . PC3 . . . . . 216 207
. . . 12 . . . . . . . . . . . . . 208 591
. . . 13 . . . . . . . . . . . . . 212 038
. . . 14 . . . . F1 . . . . . 225 514
. . . 15 . . . . . . . . . . . . . 225 553
. . . 16 . . . . . . . . . . . . . 229 382
. . . . . . . . PLG32 . . . . 115 091
. . . . . PLG33-38,54 . 131 204
. . . . . . PLG51,57 . . . 115 093
. . . . . . . . PLG58 . . . . 115 094
. . . . . . . . . . . . . . . . . . . 227 082
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
WINDTUNNEL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, AC commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDOFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . .
GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . .
WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . .
STAND−OFF,NO 6−32 X .500 LG .250 hex stl m&f . . . . . . . . . . . . . . . . .
BRACKET, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, tank cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPORT, leads bridge output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, circuit card assy intrcnct bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . .
SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE, crtg 2. amp 600 V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER, fuse crtg 30 A 600 V 13/32 X 1−1/2 LG . . . . . . . . . . . . . . . . . . .
SUPPORT, leads bridge output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHOKE, common mode (400 V model only) . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
2
2
6
1
1
1
1
1
12
8
1
1
1
1
7
2
1
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 58
. Hardware is common and
not available unless listed.
2
1
4
3
804 223-A
Figure 11-6. Capacitor Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-6. Capacitor Assembly
...
...
...
...
1
2
3
4
. . C3-C6 . . . . 218 685
. . . . . . . . . . . . . 218 688
. . . . . . . . . . . . {221 419
. . . . . . . . . . . . . . 602 211
..
..
..
..
CAPACITOR, popyp met film 1.5 uf 700 VAC . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M8 −1.2 x 12 soc hd−zinc cls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock .318 ID X 0.586 OD X .078T STL PLD SPLIT.312 . . . . . .
4
2
40
40
*Recommended Spare Parts.
{Torque screws to 50 in lbs (5.6 N⋅m ).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 59
. Hardware is common and
not available unless listed.
20
6
1
2
19
5
7
4
8
18
16
17
14
9
10
11
3
12
15
13
804 224-E
Figure 11-7. Right Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Right Windtunnel
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . . . . . . . . . . . 216 630
. . . . . . . . . . . . . 213 873
. . . . . . . . . . . . . 213 871
. . . . . . . . . . . . . 170 647
. . . . . . . . . . . . . 223 120
. . . . . . . . . . . . . . 115 443
. . . . . . . . . . . . . 148 743
. . . RT1 . . . . . 222 326
. . . . . . . . . . . . . 083 147
. . . . . . . . . . . . . 224 391
. . . . . . . . . . . . . 605 339
. . . PC4 . . . . . 228 407
. . . . . . . . . . . . . 212 038
. . . . . . . . . . . . . 176 879
. . . PC8 . . . . . 228 262
. . . . . . . . . . . . . 208 591
OM-222 166 Page 60
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . .
BLOCK, term 115 amp 3 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUG, univ w/scr 600V 2−14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . .
GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . .
PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . .
KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, bus intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
5
1
1
2
1
2
1
2
12
1
14
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Right Windtunnel (Continued)
. . . 17 . . . . . . . . . . . . . 229 728
. . . 18 . . . PC6 . . . . . 216 262
. . . 19 . . . . . . . . . . . . . 030 170
. . . 20 . . . . . . . . . . . . . 231 050
. . . . . . PLG64,410,
411 . . . . . . 115 093
. . . . . . . . PLG47 . . . . 115 091
. . . . . . PLG45,61 . . 131 204
. . . . . . . . PLG62 . . . 201 665
. . . . . . . . PLG63 . . . . 115 094
. . . . . PLG111, 112
121, 132,
141, 142 . . . 131 054
..
..
..
..
STRAP, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, cooler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap−in nyl .750 id x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . .
ASSY, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1
1
1
..
..
..
..
..
HOUSING
HOUSING
HOUSING
HOUSING
HOUSING
3
1
2
1
1
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
(SERVICE
(SERVICE
(SERVICE
(SERVICE
(SERVICE
KIT)
KIT)
KIT)
KIT)
KIT)
..........................
..........................
..........................
..........................
..........................
. . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 61
. Hardware is common and
not available unless listed.
22
1
6
2
21
4
7
8
17
16
19
5
14
9
10
11
3
20
12
18
15
13
804 431-E
Figure 11-8. Right Windtunnel (400 V Model Only)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-8. Right Windtunnel (400 V Model Only)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . . . . . . . . . . 216 630
. . . . . . . . . . . . . 213 873
. . . . . . . . . . . . . 213 871
. . . . . . . . . . . . . 170 647
. . . PC9 . . . . . 225 356
. . . . . . . . . . . . . . 115 443
. . . . . . . . . . . . . 148 743
. . . RT1 . . . . . 222 326
. . . . . . . . . . . . . 083 147
. . . . . . . . . . . . . 224 391
. . . . . . . . . . . . . 605 339
. . . PC4 . . . . . 228 407
. . . . . . . . . . . . . 212 038
. . . . . . . . . . . . . 226 579
. . . . . . . . . . . . . 176 879
. . . . . . . . . . . . . 226 041
. . . PC6 . . . . . 216 262
. . . PC8 . . . . . 228 262
OM-222 166 Page 62
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, input filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUG, univ w/scr 600V 2−14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . .
GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . .
PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . .
KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg ce filter ground plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, cooler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, bus intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
5
1
1
6
1
2
1
2
1
12
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-8. Right Windtunnel (400 V Model Only) (Continued)
. . . 19 . . . . . . . . . . . . . 208 591
. . . 20 . . . . . . . . . . . . . 229 728
. . . 21 . . . . . . . . . . . . . 030 170
. . . 22 . . . . . . . . . . . . . 231 050
. . . . . . PLG64,410,
411 . . . . . . 115 093
. . . . . . . . PLG47 . . . . 115 091
. . . . . . PLG45,61 . . 131 204
. . . . . . . . PLG62 . . . 201 665
. . . . . . . . PLG63 . . . . 115 094
. . . . . PLG111, 112
121, 132,
141, 142 . . . 131 054
..
..
..
..
SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . .
STRAP, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap−in nyl .750 id x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . .
ASSY, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
4
1
1
..
..
..
..
..
HOUSING
HOUSING
HOUSING
HOUSING
HOUSING
3
1
2
1
1
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
PLUG+SKTS,
(SERVICE
(SERVICE
(SERVICE
(SERVICE
(SERVICE
KIT)
KIT)
KIT)
KIT)
KIT)
..........................
..........................
..........................
..........................
..........................
. . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 63
. Hardware is common and
12
not available unless listed.
1
10
8
2
6
13
7
14
3
15
5
4
11
9
804 225-A
Figure 11-9. Left Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-9. Left Windtunnel
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
11
12
13
14
15
. . . . . . . . . . . . . 216 631
. . . . . . . . . . . . . 218 683
. . . . . . . . . . . . . 170 647
. . . . . . . . . . . . . 025 248
. . . . . . . . . . . . . . 115 443
. . . . . . . . . . . . . 083 147
. . . RT3 . . . . . 222 327
. . . . . . . . . . . . . 030 170
. . . . . . . . . . . . . 218 430
. . . . . . . . . . . . . 220 825
. C7-C10 . . . 218 687
. C7-C10 . . . 225 775
. . . . T2 . . . . . 219 002
. . . PC7 . . . . . 225 558
. . . PC1 . . . . . 227 027
. . . . . . . . . . . . . 212 038
OM-222 166 Page 64
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . .
STAND-OFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . .
STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . .
THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl .750 ID x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . .
COVER, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp film 1.35 uf 700 VAC +5% −0% . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp film 1.10 uf 700 vac +5% −0% (400 V model only)
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, circuit card assy intrcnct I srce out . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, power source control . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M4 − .7 x 8.5 pan hd−phl stl pld slffmg . . . . . . . . . . . . . . . . . . . . .
1
1
2
8
7
2
1
1
1
4
4
4
1
1
1
8
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-9. Left Windtunnel (Continued)
. . . . . . . PLG16,
121,122 . . . 131 054
. . . . . . . PLG19,
120 . . . . . . 115 094
. . . . . . . PLG15,
118 . . . . . . 115 093
. . . . . . . PLG77,
119 . . . . . . 115 092
. . . . . . . . PLG17 . . . . 115 091
. . . . . . . PLG18,
116 . . . . . 131 056
. . . . . . . PLG13,
113 . . . . . 162 382
. . . . . . . . PLG14 . . . 130 203
. . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 65
. Hardware is common and
not available unless listed.
4
5
3
2
1
3
4
6
7
8
1
9
804 300-A
Figure 11-10. Hermaphroditic Blank Plug Assy
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-10. Hermaphroditic Blank Plug Assy
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
.............
.............
.............
.............
.............
.............
.............
.............
.............
221 440
221 443
221 099
136 343
224 261
221 438
221 437
221 442
225 919
..
..
..
..
..
..
..
..
..
O-RING, .737 ID x .103 CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOCKET ASSY, radsok 14 mm cable end . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, K50 x 20 pan hd-phl stl pld pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP, plug assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLLAR, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAINER, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, radsok 14 mm cable end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHELL ASSY, connector - protective plug . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
2
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 66
4
1
3
2
6
7
5
8
804 324-A
Figure 11-11. Air−Cooled Output Extension Cables
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-11. Air−Cooled Output Extension Cables 195 404, 195 405, And 300 362
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
.............
.............
.............
.............
.............
.............
.............
.............
225 918
221 438
221 099
136 343
225 968
224 259
228 296
197 635
..
..
..
..
..
..
..
..
SHELL ASSY, connector − air cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Collar, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, k50x 20 pan hd−phl stl pld pt thread forming . . . . . . . . . . . . . . . .
SHELL, connector cable female with seal . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, strain relief socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, ka35x10 pan hd−phl sst pln pt thread forming . . . . . . . . . . . . . . .
LABEL, warning flexible induction cords . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
4
4
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 67
4
1
2
3
6
5
6
7
5
11
8
4
9
10
3
804 411-A
Figure 11-12. Liquid−Cooled Output Extension Cables
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-12. Liquid−Cooled Output Extension Cables (195 402, 195 403, And 300 180)
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
225 917
221 438
221 099
136 343
210 912
204 954
224 148
224 147
224 258
228 296
197 635
..
..
..
..
..
..
..
..
..
..
..
Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw K50 x 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Connect Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief Pin Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw KA35x10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
4
4
2
2
4
4
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 68
2
3
1
6
4
5
6
804 404-A
Figure 11-13. Heating Cables
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-13. Heating Cables (300 045, 300 046, 300 047, And 400 049)
...
...
...
...
...
...
1
2
3
4
5
6
.............
.............
.............
.............
.............
.............
225 968
204 954
210 912
224 259
228 296
197 635
..
..
..
..
..
..
Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, KA35x10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
4
4
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 69
1
201 432-G
Figure 11-14. Quick Connect To Quick Connect Hose
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-14. Quick Connect To Quick Connect Hose (204 877)
. . . 1 . . . . . . . . . . . . . . 204955 . . Ftg, Plstc Coupler Qdisc X 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 70
Effective January 1, 2008
(Equipment with a serial number preface of LJ or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You 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 expertise of the
distributor and Miller is
there to help you, every
step of the way.
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 conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* 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 True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
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 are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
3.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2008-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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.
PRINTED IN USA
© 2008 Miller Electric Mfg. Co. 2008−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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