Miller | LF500112G | 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 166C
2005−12
Processes
Induction Heating
Description
Induction Heating Power Source
ProHeat 35
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 − MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION . . . . . . . . . . . . . . . . . . .
2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien . . . . . . . . . . . . . . . . . . .
2-2. Informations concernant les champs électro-magnétiques (Information EMF) . . . . . . . . . . . . . . . . . . .
2-3. PRINCIPALES NORMES DE SÉCURITÉ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting Input Power For 400 V Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Temperature Recorder Receptacle RC9 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Temperature Recorder Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Locating Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Attaching Welded Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Using Contact Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Placing Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
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4
5
6
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7
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9
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10
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11
12
12
13
14
15
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TABLE OF CONTENTS
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. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
35
38
39
39
40
41
41
41
42
42
42
42
43
43
44
44
45
45
46
49
50
52
Declaration of Conformity for
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
ProHeat 35
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_stat_6/05
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE
USING
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
safety_ihom 5/05
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
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
Y 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.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
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
D
D
D
Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
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.
D
D
D
SIGNIFICANT DC VOLTAGE exists in inverter-type
power sources after removal of input power.
D
FUMES AND GASES can be hazardous.
Do not touch live electrical parts.
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 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!
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
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly grounded
receptacle outlet.
When making input connections, attach proper grounding
conductor first − double-check connections.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
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 Do not overheat parts and adhesive.
D Watch for fire; keep extinguisher nearby.
D Keep flammables away from work area.
Do not locate unit on, over, or near combustible surfaces.
D
D
Do not install unit near flammables.
Do not operate unit in explosive atmosphere.
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.
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 ADHESIVE 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 pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near induction heating operations.
OVERUSE can cause OVERHEATING
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 Miller/Hobart replacement
parts.
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
Y 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.)
Y 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:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y 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).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
OM-222 166 Page 2
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 offer 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 Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding or induction heating operations. If cleared by your doctor, then
following the above procedures is recommended.
OM-222 166 Page 3
SECTION 2 − MESURES DE SECURITE POUR LE
CHAUFFAGE PAR INDUCTION
ihom_fre 8/03
AVERTISSEMENT
LE CHAUFFAGE PAR INDUCTION peut être dangereux.
PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE
MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS D’UN STIMULATEUR CARDIAQUE DOIVENT
PREALABLEMENT CONSULTER LEUR MEDECIN.
Pendant les opérations de chauffage, comme dans la plupart des activités, l’opérateur s’expose à certains dangers.
Le chauffage n’est pas dangereux à condition de prendre certaines mesures. Les consignes de sécurité indiquées
ci-après ne sont qu’un résumé des informations plus détaillées se trouvant dans les normes de sécurité énumérées
à la page suivante. Lire et respecter toutes les normes de sécurité.
LES OPERATIONS D’INSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT
ETRE CONFIEES QU’A DU PERSONNEL QUALIFIE.
Danger de mort PAR ELECTROCUTION.
Le contact de composants électriques peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de puissance et les connexions de
sortie sont sous tension lorsqu’on active la sortie. 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.
1.
2.
3.
4.
5.
6.
Ne pas toucher des composants électriques sous tension.
Envelopper les connexions et raccords de refroidissement pour
éviter tout contact accidentel.
Porter des gants d’isolation secs, sans trous, et une protection
corporelle.
Isolez-vous de la pièce et du sol avec des tapis ou des
couvertures d’isolation suffisamment grands pour prévenir tout
contact physique avec la pièce ou la terre.
Déconnecter l’alimentation avant d’installer l’appareil ou d’en
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).
Utiliser seulement des tuyaux non conducteurs avec une
longueur minimale de 460 mm pour assurer l’isolement.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Installer et mettre cet équipement correctement à la terre
conformément au manuel utilisateur et aux codes nationaux,
gouvernementaux et locaux.
Vérifier souvent la terre de l’alimentation − contrôler et s’assurer
que le conducteur de terre du câble d’alimentation est
correctement relié à la borne de terre dans le boîtier de
déconnexion ou que le connecteur est branché à une sortie de
boîtier correctement mise à la terre.
En réalisant des connexions d’entrée brancher d’abord le
conducteur de terre approprié − contrôler deux fois les
connexions.
Vérifier souvent le bon état du câble d’alimentation ou l’isolation
des fils − remplacer le câble immédiatement s’il est endommagé −
des fils dénudés peuvent provoquer des accidents mortels.
Arrêter tous les équipements lorsqu’ils ne sont pas utilisés.
Ne pas utiliser des câbles usés, endommagés, sous
dimensionnés ou mal épissés.
Ne pas porter les câbles autour de votre corps.
Ne pas toucher le circuit électrique si vous êtes en contact avec la
pièce, la terre ou le circuit électrique d’une autre machine.
Utiliser seulement des équipements bien entretenus. Réparer ou
remplacer immédiatement des composants endommagés.
Effectuer des travaux d’entretien sur l’appareil selon le manuel.
Porter un harnais de sécurité pour effectuer des travaux
au-dessus du sol.
Maintenir solidement en place tous les panneaux et couvercles.
LE CHAUFFAGE PAR INDUCTION peut
provoquer des blessures ou des
brûlures au contact de PIECES
CHAUDES OU DE L’EQUIPEMENT.
1.
LE CHAUFFAGE PAR INDUCTION peut
provoquer un incendie.
La mise en place de l’appareil sur, au-dessus ou à
proximité de surfaces inflammables peut être source
d’INCENDIES OU d’EXPLOSION.
1. Ne pas surchauffer les composants ni les
adhésifs.
2. Attention aux risques d’incendie: tenir un
extincteur à proximité.
3. Stocker des produits inflammables hors de la
zone de travail.
OM-222 166 Page 4
2.
3.
Ne pas toucher ou manipuler la tête/l’enroulement à induction
pendant le fonctionnement.
Tenir les bijoux et autres objets personnels en métal éloignés de
la tête/de l’enroulement pendant le fonctionnement.
Laisser refroidir les composants ou équipements avant de les
manipuler.
1. Ne pas placer l’appareil sur, au-dessus ou à proximité de
surfaces infllammables.
2. Ne pas installer l’appareil à proximité de produits inflammables
3. Ne pas faire fonctionner l’appareil en atmosphère explosive.
DES FUMEES ET DES GAZ peuvent
être dangereux pour votre santé.
Le chauffage à induction génère des fumées et des
gaz. Leur inhalation peut être dangereuse pour votre
santé.
1. Eloigner la tête des fumées. Ne pas respirer les fumées.
2. A l’interieur, ventiler la zone et/ou utiliser un extracteur pour
l’évacuation des fumées et des gaz.
3. Si la ventilation est insuffisante, utiliser un respirateur à
alimentation d’air homologué.
4. Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les adhésifs, les métaux, les
consommables, les revêtements, les nettoyants et les
dégraisseurs.
5. 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.
6. 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.
7. Ne pas chauffer 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 chauffés.
2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien
LA CHUTE DE MATERIEL peut provoquer
des blessures personnelles graves et endommager les équipements.
1. Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever
l’appareil.
2. Déplacer l’appareil à l’aide d’un charriot ou d’un
engin similaire.
3. Pour les appareils sans poignée utiliser un équipement d’une capacité appropriée pour soulever
l’appareil.
4. 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.
LA PROJECTION DE PIECES DE METAL ou
DE COLLE peut provoquer des blessures
aux yeux.
1. Porter des lunettes de protection avec des protections latérales.
DES
ORGANES
MOBILES
provoquer des blessures.
peuvent
1. S’abstenir de toucher des organes mobiles tels que
des ventilateurs.
2. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
UNE UTILISATION INTENSIVE peut provoquer un SURCHAUFFEMENT DU MATERIEL.
1. Prévoir une période de refroidissement
2. Réduire le courant de sortie ou le facteur de marche
avant de recommencer le chauffage.
3. Respecter le facteur de marche nominal.
L’ELECTRICITE STATIQUE peut endommager les composants des tableaux électriques.
1. Etablir la connexion avec la barrette de terre avant
de manipuler des cartes ou des pièces.
2. Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
Il subsiste DU COURANT CONTINU IMPORTANT après la mise hors tension de l’alimentation électrique.
1. Avant de toucher des organes internes, arrêter la
source électrique, débrancher l’alimentation, et décharger les condensateurs d’alimentation conformément aux instructions indiquées dans la partie maintenance.
LE RAYONNEMENT HAUTE FREQUENCE
peut provoquer des interférences avec les
équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.
•
•
DES CHAMPS MAGNETIQUES CREES PAR
DES COURANTS ELEVES peuvent affecter le
fonctionnement du stimulateur cardiaque.
1. Porteurs de stimulateur cardiaque, restez à distance.
2. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher
des opérations de chauffage à induction.
•
•
•
Demander seulement à des personnes qualifiées
familiarisées avec des équipements électroniques
de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par
un électricien qualifié les interférences résultant de
l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de
l’installation.
Maintenir soigneusement fermés les portes et les
panneaux des sources de haute fréquence.
OM-222 166 Page 5
2-2. Informations concernant les champs électro-magnétiques (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 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 stimulateurs cardiaques
Les procédures ci-dessus concernent également les porteurs de
stimulateur cardiaque. Consulter votre médecin pour un complément
d’information.
2-3. PRINCIPALES NORMES DE SÉCURITÉ
Normes de sécurité et de santé, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Code électrique national, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-222 166 Page 6
Code électrique du Canada, partie 1, CSA Standard C22.1, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard,Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
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
3-1.
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
3-2. Rating Label For CE Products
For label location
see Section 4-2.
226 534-A
3-3. Symbols And Definitions
Note
A
IP
Some symbols are found only on CE products.
Amperes
Degree Of
Protection
V
Hz
Increase
Volts
Alternating Current
Hertz
Circuit Breaker
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. Specifications
Rated Output
Output
Frequency
5 To 30
kHz
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
Length: 36-3/4 in
(993 mm)
Width: 21-1/2 in
(546 mm)
Height: 29 in
(737 mm)
227 lb
(103 kg)
kW
37
*While idling
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,
computers, and communications equipment.
•
•
•
•
•
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.
OM-222 166 Page 10
4-2. Selecting A Location
1. Lifting Eye
2. 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. Rating Label (Non CE Models
Only)
Use rating label to determine input
power needs. Label located under
front access door.
OR
2
4. Plate Label (CE Models Only)
Label located under power switch.
5. Rating Label (CE Models
Only)
Location And Airflow
6
Use rating label to determine input
power needs.
6. Line Disconnect Device
3
Locate unit near correct input
power supply.
18 in
(460 mm)
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
4
5
18 in
(460 mm)
803 992-B
OM-222 166 Page 11
4-3. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
4-4. Electrical Service Guide
50 Hz
Three
Phase
60 Hz Three Phase
400
460
575
60
50
40
Circuit Breaker 1, Time-Delay 2
70
61
45
Normal Operating 3
80
70
60
6
8
8
254
(77)
214
(65)
334
(102)
8
8
10
Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
1
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “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).
4 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.
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
OM-222 166 Page 12
4-5. Connecting Input Power
Tools Needed:
3/8 in
4
7
8
2
3
L1
L2
L3
6
5
1
12
9
13 10 11
Ref. 803 994-B
Y Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Select size and length using Section 4-4.
Conductor rating must comply with national,
state, and local electrical codes.
Y Disconnect and lockout/tagout input
power before connecting input conductors from unit.
2. Disconnect Device Of Proper Rating
(Switch Shown In The Off Position)
3. Green Or Green/Yellow Grounding
Conductor
4. Disconnect Device Grounding Terminal
5. Input Conductors (L1, L2 And L3)
6. Disconnect Device Line Terminals
Y Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
. 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.
1. Input Power Cord
. If using
individual grounding and input
conductors, install in conduit or equivalent
to deenergized line disconnect device.
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2 and L3 to
disconnect device line terminals.
7. Over-Current Protection
Select type and size of over-current protection
using Section 4-4. Install into deenergized line
disconnect device (fused disconnect switch
shown).
8. Primary Cover
Open primary cover.
9. Input Conductors
10. Grounding Conductor
11. Strain Relief Connector
Route input power cord through strain relief on
rear panel to fuse block.
12. Input Junction Block
13. Power Source Ground Terminal
Connect grounding conductor to ground
terminal first. Then connect input conductors
to junction block.
Reinstall fuse block cover.
Tighten strain relief. Close and secure primary
cover.
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
OM-222 166 Page 13
4-6. Connecting Input Power For 400 V Model
Tools Needed:
3/8 in
4
7
8
2
3
L1
L2
L3
6
5
1
12
9
13
10 11
Ref. 804 430-A
Y Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Select size and length using Section 4-4.
Conductor rating must comply with national,
state, and local electrical codes.
Y Disconnect and lockout/tagout input
power before connecting input conductors from unit.
2. Disconnect Device Of Proper Rating
(Switch Shown In The Off Position)
3. Green Or Green/Yellow Grounding
Conductor
4. Disconnect Device Grounding Terminal
5. Input Conductors (L1, L2 And L3)
6. Disconnect Device Line Terminals
Y Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
. 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.
1. Input Power Cord
. If using
individual grounding and input
conductors, install in conduit or equivalent
to deenergized line disconnect device.
OM-222 166 Page 14
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2 and L3 to
disconnect device line terminals.
7. Over-Current Protection
Select type and size of over-current protection
using Section 4-4. Install into deenergized line
disconnect device (fused disconnect switch
shown).
8. Primary Cover
Open primary cover.
9. Input Conductors
10. Grounding Conductor
11. Strain Relief Connector
Route input power cord through strain relief on
rear panel to fuse block.
12. Input Filter Circuit Board
13. Power Source Ground Terminal
Connect grounding conductor to ground
terminal first. Then connect input conductors
to junction block.
Reinstall fuse block cover.
Tighten strain relief. Close and secure primary
cover.
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
4-7. 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.
2.
3.
4.
5.
Output Connector 1
Output Connector 2
Protective Plug
Air-Cooled Extension Cable
Liquid-Cooled Extension Cable
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.
Dual Air-Cooled Output Connection
Single Air-Cooled Output Connection
Connect air-cooled output extension
cables to Output Connector 1 and Output
Connector 2.
Connect air-cooled output extension cable
to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.
Single Liquid-Cooled Output Connection
Connect liquid-cooled output extension
cable to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.
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: 25 ft (7.6 m) or 50 ft (15.2 m).
OM-222 166 Page 15
4-8. 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 4-9)
To connect to receptacle, align keyway, insert plug and tighten
threaded collar.
4
I
H
F
G
2
1
803 993-C
4-9. Remote 14 Socket Information
Socket
Socket Information
A
Remote Contactor
B
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
Current No. 2 output
p signal
g
RMS ((1 volt/100 amperes).
p
)
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
Ch
Chassis
i common.
OM-222 166 Page 16
4-10. Temperature Recorder Receptacle RC9 Information And Connections
1. Plug
2. Threaded Collar
3. Temperature Recorder
Receptacle RC9 (See Section
4-11)
3
2
To connect to receptacle, insert
plug and tighten threaded collar.
1
2
1
803 993-C
4-11. 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
OM-222 166 Page 17
4-12. 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. Receptacles
2. Plug
To connect plug, align key with keyway, insert end into receptacle, and
rotate plug until tight.
3. Handle
4. 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 18
4-13. 115 Volt AC Duplex Receptacle And Supplementary Protector
1. 115 VAC 2.5 A Single-Phase
AC Receptacle RC1
2. 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
4-14. 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.
OM-222 166 Page 19
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.
9.
The following describes the thermocouple routing from work to power source.
S
Type K, 20 awg solid 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 20
4-15. Attaching Welded Thermocouples
NOTE
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.
Note: 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 21
4-16. 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.
Note: 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.
4-17. 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 22
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.
2. TC1−4 Temperature Display
Provides temperature display of thermocouples 1 through 4.
3. Control Thermocouple LED’s
LED’s indicate which thermocouples (1−4)
are used to control the heating process.
4. Temperature Units LED’s
LED’s indicate units for temperature measurements (°F or ° C).
5. Fault LED
LED lights to indicate a system fault condition.
6. Limit LED
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
Use button to stop a heating process.
9. Hold Button
Use button to hold a heating process.
10. Run Button
Use button to run a heating process.
11. Cursor Button
Use button to move selection cursor in the
4 x 40 LCD display (item 18.).
12. Program Button
Use button to program the process control.
13. Run Status Button
Use button to display “real time” operating
status.
14. Parameter Button
Use button to display “real time” power
source operating parameters.
15. Cooler Button
Use button to turn cooler On and Off.
16. Increase Button
Use button to increase values in set-up
screen.
17. Decrease Button
Use button to decrease value in program
screen.
18. 4 x 40 LCD Display
Displays programming, runs status, parameter, fault and limit conditions, and troubleshooting guide.
19. Thermocouple Input Receptacles
Use receptacles for type K thermocouple
inputs.
OM-222 166 Page 23
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 liquidcooled 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 4-7).
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”
and the following screen will appear on the display:
System Setup Screen
Degree Units . : >°F
SYSTEM SETUP
Tolerance. . . . . :
±25
Input Type . . . :
K TC
Control Mode: Temp
Power Output :
35kW
System Lock: No
Backlight: Yes
To change a setting:
S
Press the “Cursor”
S
Press “Increase”
OM-222 166 Page 24
button to move the cursor to the parameter to be changed
or “Decrease”
button to select desired set-up feature.
buttons
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 LED’s.
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”.
or “Decrease”
Control Mode − press the “Increase”
button to select the desired method of system
control, either “Temperature” or “Manual”. For more details about methods of control, see Section or .
S
The factory default is temperature based control.
or “Decrease”
Power Output − press the “Increase”
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).
OM-222 166 Page 25
NOTE
All parameters in “System Setup” are considered global, and any changes to the
system set-up parameters will apply to all programs.
To reset the system back to factory default settings, simultaneously press and hold the “Increase”
and
buttons, and turn on the power source.
“Decrease”
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”
the “Increase”
OM-222 166 Page 26
button to move the cursor to the desired selection (Temperature or Soak Time), and press
or “Decrease”
button to change the value to the desired setting.
NOTE
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 1000 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)
6-4-1-2. 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. :
Cool Temp . :
600
200
Soak Time : 01:00:00
Cool Rate :
600 °/Hr
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 (Soak Temperature, Soak Time, Cool
Temperature, or Cool Rate), and press the “Increase”
or “Decrease”
button to change the value to
the desired setting.
OM-222 166 Page 27
NOTE
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 1000
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
Ramp Temp. :
Cool Temp . :
Ramp Rate : 600 °/Hr
600
200
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”
the desired setting.
OM-222 166 Page 28
or “Decrease”
button to change the value to
NOTE
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:
NOTE
This is the screen for initial use of the system. Subsequent use of custom program
will revert to the last program used.
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”
“Increase”
button to move the cursor to the desired selection (Type or Control TC), and press the
or “Decrease”
button to change the value to the desired setting. When the cursor is
moved to the “Type” selection, pressing the “Increase”
or “Decrease”
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.
OM-222 166 Page 29
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”
600
button to move the cursor to the “Temperature” position and the initial temperature can be
adjusted using the “Increase”
Pressing the “Cursor”
or “Decrease”
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:
Custom Program Screen
Mode . . . . . . :
Custom Program
Segment . . . . :
2
Type. . . . . . . . : >Ramp
Temperature. . :
Use the “Cursor”
“Increase”
600
Ramp Rate: 600 °/Hr
button to move the cursor to the “Temperature” or “Ramp Rate” position and use the
or “Decrease”
button to set the desired value.
When the cursor is in the “Ramp Rate” position, pressing the “Cursor”
the program to the next segment number.
OM-222 166 Page 30
button again automatically advances
Soak Function
When type is set to “Soak”, the following screen appears on the display:
Custom Program Screen
Mode . . . . . . :
Segment . . . . :
Custom Program
3
Type. . . . . . . . : >Soak
Soak Time. . . . :
Use the “Cursor”
“Decrease”
01:00:00
button to move the cursor to the “Soak Time” position and use the “Increase”
or
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 . . . . . . . :
Segment . . . . . :
Custom Program
4
Type. . . . . . . . . : >End
Control TC. . . . :
1,2,3,4
The only changeable parameter in the “End” segment is selecting the number of thermocouples. Use the “Cursor”
button to move the cursor to the “Control TC” position. 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.
A custom program can contain up to 10 segments. To view Program parameters, position the cursor at segment
and use the “Increase”
or “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 31
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 . . . . . . :
Segment . . . . :
Custom Program
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 . . . . . . :
Segment . . . . :
Custom Program
3
Type. . . . . . . . : >Soak
Soak Time. . . . :
01:00:00
Soak at 1250 degrees F for a period of 1:00.
Custom Program Screen
Mode . . . . . . :
Segment . . . . :
Custom Program
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 . . . . . . . :
Segment . . . . . :
Custom Program
5
Type. . . . . . . . . : >End
Control TC. . . . :
1,2,3,4
End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.
OM-222 166 Page 32
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:
Custom Program Screen
Mode . . . : Custom Program
Command. :
Run Time
:
Power. : 0.0 KW
0.0 KW
Current :
0A
>00:00:00
Voltage :
0V
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”
and “Decrease”
buttons. A message will display “Press Program to reset factory defaults”. Release the “Increase”
“Decrease”
buttons, and press the “Program”
and
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
Target Temp :
−−−−−−
Countdown :
−−:−−:−−
Status. . . . . . :
TC5 : 75
TC6 : 75
Stopped
“Mode” displays the programming mode (Preheat, Bake-Out or PWHT). 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.
OM-222 166 Page 33
6-5-1-2. Custom Program
Run Status Screen
Mode . . . . . : Custom Program
Target Temp :
TC5 : 75
−−−−−−
TC6 : 75
Countdown : −−:−−:−−
Status. . . . . . :
Stopped
Segment :
1
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.
6-5-2.
Manual Control
Run Status Screen
Mode . . . . . . : Manual
TC5 : 75
Power . . . . :
TC6 : 75
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.
NOTE
No changes can be made to the run status screen, and the “Cursor” button and the
“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
Current . . :
0A
Voltage . . :
0V
TC5 : 77
TC6 : 77
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
OM-222 166 Page 34
initiating a heating cycle, the system will automatically start the cooler when the “Run”
Pressing the “Stop”
“Cooler”
button is pressed.
button does not shut off the cooler. The cooler must be shut off separately by pressing the
button.
When power source output is energized, the cooler cannot be turned off. If the “Cooler”
button is pressed while
output is energized, the following screen will appear on the display:
Cooler Message Screen
Cooler cannot be turned off
while output is on.
NOTE
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 LED’s
illuminate and the following screen appears on the display:
Power Up Message Screen
ProHeat 35
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 display indicates “OPEN”.
S
“Control” LED’s illuminate to indicate the number of control TC’s in the last program.
S
The appropriate degree units (°F or °C) light illuminates.
OM-222 166 Page 35
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”
button will
button yellow indicator LED illuminates and
initiate a heating cycle. When a program run is initiated, the “Run”
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.
In addition, when running in “Manual” operating mode, the “Hold”
running in “Manual” operating mode, pressing the “Hold”
button is not functional. If the system is
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 parameters 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.
OM-222 166 Page 36
To make changes to a program while in run mode, press the “Hold”
button and the yellow indicator LED will
button yellow indicator LED will turn off. When in hold, the system will maintain the
illuminate, and the “Run”
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.
NOTE
Regardless of the program status or power source operating status, pressing the
“Stop” button will terminate output power and reset the program. In the case of
Custom Programs, the system will reset to Segment 1.
OM-222 166 Page 37
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 5-1. 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 step
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
Note 1: Above 25.7 kHz, the output dwells back to linearly decrease the output amperage to a maximum of 175
amperes per output at 30 kHz. In this frequency range (25.7 − 30 kHz), the system will deliver the level of current
dictated by the linear amperage decrease, and then step down to 150 amperes per output after 15 minutes.
Note 2: Above 20 kHz, the output dwells back to linearly decrease the output amperage to a maximum of 175 amperes
per output at 30 kHz. In this frequency range (20 − 30 kHz), the system will deliver the level of current dictated by the
linear amperage decrease.
OM-222 166 Page 38
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
2
1
Clean Output
Connector
Contacts
2
1
Clean Ground
Sense Lead
Receptacles
Repair Or Replace
Cracked Cables
And Cords
2
1
Clean Operator
Interface Overlay
Check Integrity Of
Protective Plug,
Replace If Necessary
6 Months
Blow Out Or
Vacuum Inside
Of Wind Tunnel
OM-222 166 Page 39
7-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front louvers and back slots
as shown.
803 992-B
OM-222 166 Page 40
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING
8-1. Symbol Usage
safety_ihom 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
8-2. Induction Heating Hazards
Y 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 8-4. Read and follow all
Safety Standards.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D
INDUCTION HEATING can cause burns.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
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
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Do not touch live electrical parts.
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.
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding
conductor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
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.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
D
D
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.
Allow cooling period before handling parts or equipment.
Keep metal jewelry and other metal personal items away from
head/coil during operation.
FIRE OR EXPLOSION hazard.
D
D
D
D Do not overheat parts and adhesive.
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 unit in explosive atmosphere.
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 exhaust to remove fumes
and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read 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 if necessary, while
wearing an air-supplied 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 41
8-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury.
D
OVERUSE can cause OVERHEATING
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 Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.
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.
FLYING METAL OR ADHESIVE can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
H.F. RADIATION can cause interference.
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 pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near induction heating operations.
D
D
D
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
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.
8-4. Principal Safety Standards
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
8-5. California Proposition 65 Warnings
Y 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.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y 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 Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
8-6. EMF Information
Considerations About Induction Heating And The Effects Of Low Frequency Electric And Magnetic Fields
fer clear science-based advice on strategies to minimize or avoid
potential risks.”
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,
OTA-BP-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-
To reduce magnetic fields in the workplace, use the following procedures:
OM-222 166 Page 42
5. Arrange output cable to one side and away from the operator.
6. Do not coil or drape output cable around the body.
7. Keep power source and cable as far away from the operator as
practical.
About Pacemakers:
The above procedures are also recommended for pacemaker wearers.
Consult your doctor for complete information.
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 43
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.
Pressing the “Decrease”
button will acknowledge the limit and continue operation with the existing set up. In
the acknowledge state, the yellow “Limit” LED will stop flashing and remain on continuously. The LCD display will
revert to an active screen once the “Program”
button, “Run Status”
button, or “Parameters”
kW
A
V
Hz
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”
“Run”
button. After changes are made to the setup, press the
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
OM-222 166 Page 44
Limit Condition
Additional Information
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
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”
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 “Stop”
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
OM-222 166 Page 45
Fault Condition
Additional Information
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
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
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”
kW
A
V
Hz
button and pressing the “Parameters”
button.
When this feature is initially activated, the following screen appears on the LCD display:
OM-222 166 Page 46
System Diagnostic Screen
RemCmd : 1023 Off
Cable 1 : LQD
Out I1 :
0A
Cable 2 : LQD
Out I2 :
0A
ClntFR : 0.75 GPM
Isrc FB :
0A
DIAG1
ClrSts : Flowing
RemCmd − This is the value of the remote command and the status of the remote contactor from a remote command
device.
NOTE
Remote command is unsupported on this platform.
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
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”
the “Parameters”
kW
A
V
Hz
button and pressing
button.
System Diagnostic Screen
VLnA−B : 460V
Therm1 : 75
DIAG2
VLnB−C : 460V
Therm2 : 75
Therm5 :
75
VLnC−A : 460V
Therm3 : 75
ClrTmp :
77
VBus : 650V
Therm4 : 75
RmtFlw : Off
OM-222 166 Page 47
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 being used.
RmtFlw − This is the status of the relay contacts for remote coolant flow on a liquid-cooled system.
S
OFF
S
ON
NOTE
OM-222 166 Page 48
This feature is unsupported on the current platform.
9-7. Removing Wrapper and Measuring Input Capacitor Voltage
Y 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.
Tools Needed:
5/16 in
Y Turn Off welding power
source, and disconnect
input power.
Y 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.
Remove right side panel.
1
Current Source Interconnect
Board PC3
2
Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC2 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).
3
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit.
Reinstall right side panel when
finished.
1
+ lead to right bus terminal,
− lead to left bus terminal
3
2
Typical Bleeder Resistor
200 to 500 ohm, 10 watt
wire wound resistor
#16 AWG 600 Volts AC
Insulation Rating
804 226-B
OM-222 166 Page 49
SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram
OM-222 166 Page 50
218 057-D
OM-222 166 Page 51
SECTION 11 − PARTS LIST
. Hardware is common and
not available unless listed.
3
5
4
12
See Figure 11-3
13
14
15
10
9
1
7
11
6
8
See Figure 11-2
11
2
804 218-B
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 . . . . . . . . . . . . . 189 491
. . . 8 . . . . . . . . . . . . . 168 343
. . . 9 . . . . . . . . . . . . . 222 106
. . . 10 . . . FM3 . . . . . 196 887
. . . 11 . . . . . . . . . . . . . 206 270
. . . 12 . . . . . . . . . . . . . 198 035
. . . 13 . . . . . . . . . . . . . 197 931
. . . 14 . . . . . . . . . . . . . 197 900
. . . 15 . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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 52
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 53
. 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 . . . . . 604 176
. . . 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
. . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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 54
. Hardware is common and
17
not available unless listed.
2
1
3
4
7
14
15
6
9
5
8
13
16
6
10
9
12
19
18
11
Figure 11-4. Base w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
804 221-C
Quantity
Figure 11-4. Base w/Components
. . . 1 . . . . . . . . . . . . . 217 328
. . . 2 . . . . . . . . . . . . . 162 830
. . . 3 . . . . . . . . . . . . . 083 883
. . . 4 . . . . . . . . . . . . . 157 320
. . . 5 . . . . . . . . . . . . . 213 865
. . . 6 . . . . . . . . . . . . . 213 939
. . . 7 . . L1,L2 . . . . 218 692
. . . 8 . . . . . . . . . . . . . 216 815
. . . 9 . . . C1,2 . . . . 213 870
. . . 10 . . . . T1 . . . . . 213 583
. . . 10 . . . . T1 . . . . . 227 065
. . . 11 . . . . . . . . . . . . . 216 629
. . . 12 . FM1,FM2 . . 222 728
. . . 13 . . . RC4 . . . . . . 115 090
. . . 14 . . . . . . . . . . . . . 217 992
. . . 15 . . . . . . . . . . . . . 224 973
. . . 16 . . . . . . . . . . . . . . 603 115
. . . 17 . . . . . . . . . . . . . 026 627
. . . . . . . . PLG4 . . . . . 115 094
. . . 18 . . . . . . . . . . . . . 226 837
. . . 19 . . . . . . . . . . . . . 226 838
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
FRAME, lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock .402 ID x 0.709 OD x .087T stl split10 mm . . . . . . . . . . . .
SCREW, 375−16 x .75 hexwhd .78D GR5 . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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 55
. Hardware is common and
See
Figure 11-6
not available unless listed.
9
11
10
3
13
1
7
12
8
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
. . . 10 . . . PC5 . . . . . 225 556
. . . 11 . . . PC3 . . . . . 216 207
. . . 12 . . . . . . . . . . . . . 176 879
. . . 13 . . . . . . . . . . . . . 212 038
. . . 14 . . . . F1 . . . . . 225 514
. . . 15 . . . . . . . . . . . . . 225 553
. . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, circuit card assy intrcnct bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . .
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
12
8
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 56
. 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 57
. Hardware is common and
not available unless listed.
6
1
2
5
4
7
8
14
13
9
10
11
3
12
804 224-A
Figure 11-7. Right Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Right Windtunnel
. . . 1 . . . . . . . . . . . . . 216 630
. . . 2 . . . . . . . . . . . . . 213 873
. . . 3 . . . . . . . . . . . . . 213 871
. . . 4 . . . . . . . . . . . . . 170 647
. . . 5 . . . . . . . . . . . . . 223 120
. . . 6 . . . . . . . . . . . . . . 115 443
. . . 7 . . . . . . . . . . . . . 148 743
. . . 8 . . . RT1 . . . . . 222 326
. . . 9 . . . . . . . . . . . . . 083 147
. . . 10 . . . . . . . . . . . . . 224 391
. . . 11 . . . . . . . . . . . . . 605 339
. . . 12 . . . PC4 . . . . . 225 557
. . . 13 . . . . . . . . . . . . . 212 038
. . . 14 . . . . . . . . . . . . . 176 879
. . . . . . . PLG410,
411 . . . . . . 115 093
. . . . . . . . PLG47 . . . . 115 091
. . . . . . . . PLG45 . . . 131 204
..
..
..
..
..
..
..
..
..
..
..
..
..
..
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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
5
1
1
2
1
2
1
2
14
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 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 58
. Hardware is common and
6
1
not available unless listed.
2
7
5
4
16
8
15
14
13
9
11
10
3
12
804 431-A
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 . . . . . . . . . . . . . 216 630
. . . 2 . . . . . . . . . . . . . 213 873
. . . 3 . . . . . . . . . . . . . 213 871
. . . 4 . . . . . . . . . . . . . 170 647
. . . 5 . . . . . . . . . . . . . 225 356
. . . 6 . . . . . . . . . . . . . . 115 443
. . . 7 . . . . . . . . . . . . . 148 743
. . . 8 . . . RT1 . . . . . 222 326
. . . 9 . . . . . . . . . . . . . 083 147
. . . 10 . . . . . . . . . . . . . 224 391
. . . 11 . . . . . . . . . . . . . 605 339
. . . 12 . . . PC4 . . . . . 225 557
. . . 13 . . . . . . . . . . . . . 212 038
. . . 14 . . . . . . . . . . . . . 176 879
. . . . . . . PLG410,
411 . . . . . . 115 093
. . . . . . . . PLG47 . . . . 115 091
. . . . . . . . PLG45 . . . 131 204
. . . 15 . . . . . . . . . . . . . 226 579
. . . 16 . . . . . . . . . . . . . 226 041
..
..
..
..
..
..
..
..
..
..
..
..
..
..
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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
5
1
1
2
1
2
1
2
14
..
..
..
..
..
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg ce filter ground plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
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 59
. 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
. . . . . . . . . . . . . 213 683
. . . . . . . . . . . . . 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 . . . . . 217 928
. . . . . . . . . . . . . 212 038
OM-222 166 Page 60
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
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 61
. 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
.............
.............
.............
.............
.............
.............
.............
.............
.............
OM-222 166 Page 62
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
Notes
Notes
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
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’s True Blue® Limited Warranty shall not apply to:
1.
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 date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
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.
3.
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.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
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.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
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 1/05
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
© 2005 Miller Electric Mfg. Co. 10/05
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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