OM-222 166K
Processes
2007−11
Induction Heating
Description
Induction Heating Power Source
ProHeat 35
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Warning Label Definitions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Connecting 3-Phase Input Power For 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Connecting 3-Phase Input Power For 400/460 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-8. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-9. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-10. Temperature Recorder Receptacle RC9 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-11. Temperature Recorder Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-12. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-13. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-14. Locating Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-15. Attaching Welded Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-16. Using Contact Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-17. Placing Temperature Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Power Source/System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4-1. Temperature-Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4-1-1. Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4-1-2. Bake-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-4-1-3. PWHT (Post-Weld Heat Treat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-4-1-4. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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TABLE OF CONTENTS
6-5. Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5-1. Temperature Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5-1-2. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-6. Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-7. Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-8. Real-Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-9. System Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 9 − DIAGNOSTICS & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9-1. Operator Interface Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9-2. Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-3. Limit Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-4. Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-5. Fault Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-6. System Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-7. Removing Wrapper and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
. 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, Requirments 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_1/07
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
. Indicates special instructions.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Induction Heating Hazards
D
D
D
When making input connections, attach proper grounding
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
follow all Safety Standards.
conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequentlyinspect input power cord for damage or bare wiring − re-
place cord immediately if damaged − bare wiring can kill.
D
D
D
D
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.
Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch power circuit if you are in contact with the work, ground,
or another power circuit from a different machine.
During operation, keep everybody, especially children, away.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
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
improperlygrounded equipment is a hazard.
SIGNIFICANT DC VOLTAGE exists in inverter-type
power sources after removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
D
D
Do not touch live electrical parts.
Enclose any connecting bus bars and coolant fittings to prevent
unintentionalcontact.
FUMES AND GASES can be hazardous.
D
D
Wear dry, hole-free insulating gloves and body protection.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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 follow-
ing electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors,
gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or ac-
cidental contact with the workpiece or ground. For these
conditions,see ANSI Z49.1 listed in Safety Standards. And, do not
work alone!
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 re-
move fumes and gases.
D
D
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.
D
Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA 29 CFR
1910.147(see Safety Standards).
D
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson near-
by. 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 oper-
ations. 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 air-
supplied respirator. The coatings and any metals containing these
elementscan give off toxic fumes if overheated. See coating MSDS
for temperature information.
D
D
D
Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
D
D
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 pow-
er cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly grounded
receptacle outlet.
OM-222 166 Page 1
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FIRE OR EXPLOSION hazard.
INDUCTION HEATING can cause burns.
D
D
D
Do not overheat parts.
Watch for fire; keep extinguisher nearby.
Keep flammables away from work area.
D
D
Hot parts and equipment can injure.
Do not touch or handle induction head/coil
during operation.
D
Do not touch hot parts bare-handed.
D
D
D
Do not locate unit on, over, or near combustible surfaces.
Do not install unit near flammables.
D
D
Allow cooling period before handling parts or equipment.
Keep metal jewelry and other metal personal items away from
head/coilduring operation.
Do not operate where the atmosphere may contain flammable
dust, gas, or liquid vapors (such as gasoline).
D
D
After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury.
STATIC (ESD) can damage PC boards.
D
Use handle and have person of adequate
physical strength lift unit.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
D
Move unit with hand cart or similar device.
For units without a handle, use equipment of
adequatecapacity to lift unit.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D
When using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of unit.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
FLYING METAL OR DIRT can injure eyes.
D
D
D
Have only qualified person familiar with electronic equipment per-
form this installation.
D
Wear approved safety glasses with side
shields or wear face shield.
The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
MOVING PARTS can cause injury.
If notified by the FCC about interference, stop using the equip-
ment at once.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut.
READ INSTRUCTIONS.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D
Read Owner’s Manual before using or servic-
ing unit.
D
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D
Use only genuine replacement parts from the
manufacturer.
D
ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period.
Reduce output or reduce duty cycle before
starting to heat again.
D
Follow rated duty cycle.
1-4. California Proposition 65 Warnings
For Gasoline Engines:
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.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
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
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-222 166 Page 2
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1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone:1-866-512-1800) (there are 10 Regional Offices—phone for Re-
gion 5, Chicago, is 312-353-2220, website: www.osha.gov).
CanadianElectrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario,
Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044,
website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
1-6. EMF Information
ConsiderationsAbout Induction Heating And The Effects Of Low Fre-
quency Electric And Magnetic Fields
fer clear science-based advice on strategies to minimize or avoid
potentialrisks.”
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
peoplewhich clearly establish that low frequency magnetic fields can in-
teract with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientif-
ic 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 proce-
dures:
1. Arrange output cable to one side and away from the operator.
2. Do not coil or drape output cable around the body.
3. Keep power source and cable as far away from the operator as
practical.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If
cleared by your doctor, then following the above procedures is recom-
mended.
OM-222 166 Page 3
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom _2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
. Indique des instructions spécifiques.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
D
D
Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales,provinciales et locales.
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu-
ces normes de sécurité.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assu-
rer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccor-
dée à une prise correctement mise à la terre.
D
D
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et revérifier les connexions.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chau-
des.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrementles enfants.
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à
nu peut entraîner la mort.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
Le contact de composants électriques peut provo-
quer des accidents mortels ou des brûlures graves.
D
D
Ne pas enrouler les câbles autour du corps.
Ne pas toucher le circuit électrique si l’on est en contact avec la piè-
ce, la terre ou le circuit électrique d’une autre machine.
Le circuit électrique et les barres collectrices ou les
connexions de sortie sont sous tension lorsque
l’appareilfonctionne. Le circuit d’alimentation et les circuits internes
de la machine sont également sous tension lorsque l’alimentation est
sur marche. Des équipements installés ou reliés à la borne de terre de
manière incorrecte sont dangereux.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformé-
ment à ce manuel.
D
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D
D
Ne pas toucher aux pièces électriques sous tension.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Protéger toutes les barres collectrices et les raccords de refroidis-
sement pour éviter de les toucher par inadvertance.
D
D
Porter des gants isolants et des vêtements de protection secs et
sans trous.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D
Avant de toucher des organes internes, couper l’onduleur,
débrancher l’alimentation et décharger les condensateurs
d’alimentation conformément aux instructions indiquées dans la
partie maintenance.
D
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si
l’on porte des vêtements mouillés ; sur des structures métalliques telles
que sols, grilles ou échafaudages ; en position coincée comme assi-
se, à genoux ou couchée ; ou s’il y a un risque élevé de contact
inévitableou accidentel avec la pièce à souder ou le sol. Dans ces
conditions, voir ANSI Z49.1 énuméré dans les normes de sécurité.
En outre, ne pas travailler seul !
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le chauffage à induction de certains matériaux,
adhésifs et flux génère des fumées et des gaz. Leur
inhalationpeut être dangereuse pour votre santé.
D
D
Couper l’alimentation d’entrée avant d’installer l’appareil ou d’effec-
tuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation selon
la norme OSHA 29 CFR 1910.147(se reporter aux Principales nor-
mes de sécurité).
D
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces
vapeurs.
N’utiliser que des tuyaux de refroidissement non conducteurs ayant
une longueur minimale de 457 mm pour garantir l’isolation.
OM-222 166 Page 4
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D
D
D
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz.
D
D
Stocker des produits inflammables hors de la zone de travail.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces
inflammables.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs ap-
prouvé.
D
D
Ne pas installer l’appareil à proximité de produits inflammables.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les adhésifs, les
flux, les métaux, les consommables, les revêtements, les nettoyants
et les dégraisseurs.
Ne pas faire fonctionner l’appareil si l’air ambiant est chargé de parti-
cules, gaz, ou vapeurs inflammables (vapeur d’essence, par
exemple).
D
D
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace
d’étincellesincandescentes ni de flammes.
D
Travaillerdans 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
provoquerdes lésions ou des accidents mortels. S’assurer que l’air
ambiantne présente aucun danger.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
LE CHAUFFAGE PAR INDUCTION peut
provoquer des brûlures.
D
D
Ne pas chauffer dans des endroits se trouvant à proximité d’opéra-
tions de dégraissage, de nettoyage ou de pulvérisation. La chaleur
peut réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
D
Des pièces ou de l’équipement chaud peuvent
provoquer des blessures.
Ne pas surchauffer des métaux munis d’un revêtement tels que
l’acier galvanisé, plaqué au plomb ou au cadmium, à moins que le
revêtementne soit enlevé de la zone chauffée, que la zone soit bien
ventilée et, si nécessaire, en portant un respirateur. Les revêtements et
tous les métaux contenant ces éléments peuvent dégager des fumées
toxiques s’ils sont surchauffés. Voir les informations concernant la
température dans les spécifications de revêtement MSDS.
D
Ne pas toucher ou manipuler la tête/l’enroulement à induction pen-
dant le fonctionnement.
D
D
Ne pas toucher des parties chaudes à mains nues.
Laisser refroidir les composants ou équipements avant de les mani-
puler.
D
Tenir les bijoux et autres objets personnels en métal éloignés de la
tête/de l’enroulement pendant le fonctionnement.
Risque D’INCENDIE OU D’EXPLO-
SION.
D
Ne pas surchauffer les composants .
D
Attention aux risques d’incendie: tenir un ex-
tincteur à proximité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LES CHAMPS MAGNETIQUES peuvent
affecter des implants médicaux.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
D
Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soule-
ver l’appareil.
Déplacer l’appareil à l’aide d’un chariot ou d’un
engin similaire.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
D
D
D
Pour les appareils sans poignée utiliser un équipement d’une ca-
pacité appropriée pour soulever l’appareil.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D
D
Prévoir une période de refroidissement
Réduire le courant de sortie ou le facteur de mar-
che avant de recommencer le chauffage.
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
D
Respecter le cycle opératoire nominal.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits im-
primés.
D
Porter des lunettes de sécurité à coques latéra-
les ou un écran facial.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC.
D
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Maintenir fermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec-
tion.
OM-222 166 Page 5
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D
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (HF) risque de provoquer
des interférences.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence.
D
Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipe-
ments de radio-navigation et de communication,
les services de sécurité et les ordinateurs.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
2-4. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants).
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can-
cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site In-
ternet : www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
Code électrique du Canada, partie 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario, Ca-
nada L4W 5NS (téléphone : 800-463-6727 ou en Toronto416-747-4044,
site internet : www.csa-international.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone:1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute, 25
West 43rd Street, New York, NY 10036-8002 (téléphone
212-642-4900,site Internet : www.ansi.org).
:
2-6. Information EMF
Considérations relatives au chauffage à induction et aux effets des champs
électriques et magnétiques basse fréquence.
claires pour des stratégies à suivre en vue de minimiser ou de prévenir
des risques potentiels.”
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 scienti-
fique 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
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
4. Disposer le câble de sortie d’un côté à distance de l’opérateur
5. Ne pas enrouler ou draper le câble électrique autour du corps.
6. Placer la source de courant et le câble le plus loin possible de
l’opérateur.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précé-
dentes.
OM-222 166 Page 6
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
Electric shock from wiring can
kill.
1.1 Wear dry insulating gloves.
Do not wear wet or damaged
gloves.
1.2 Disconnect input plug or
power before working on
machine.
2
Induction heating can cause
injury or burns from hot items
such as rings, watches, or
parts.
2.1 Do not wear metal jewelry and
other metal personal items
such as rings and watches
during operation.
2.2 Do not touch hot parts or hot
head/coil.
3
Induction heating sparks can
cause fire. Do not overheat
parts and adhesives.
3.1 Keep flammables away from
heating operation. Do not heat
near flammables.
3.2 Heating sparks can cause
fires. Have a fire extinguisher
nearby and have a
watchperson ready to use it.
4
Breathing heating fumes can
be hazardous to your health.
Read Material Safety Data
Sheets (MSDSs) and
manufacturer’s instructions for
material used.
4.1 Keep your head out of the
fumes.
4.2 Use forced ventilation or local
exhaust to remove the fumes.
4.3 Use ventilating fan to remove
fumes.
5
Always wear safety glasses
or goggles during and around
heating operations to prevent
possible injury.
5.1 Wear either safety glasses or
full goggles depending on
type of operation and nearby
processes.
6
Do not remove or paint over
(cover) the label.
7
Become trained and read the
instructions before working on
the machine or heating.
190 025
OM-222 166 Page 7
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3-2. Warning Label Definitions (Continued)
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
2
3
2
3
Electric shock from wiring can
kill.
Overuse can cause
overheating. Follow rated duty
cycle.
4
5
6
7
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.
5
4
Connect input conductors (L1,
L2 And L3) to line terminals.
6
7
194 466
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
2
3
4
2
3
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
4
Do not touch input
capacitor(s). Allow time for
capacitor(s) to discharge.
Check input capacitor(s)
227 085-A
OM-222 166 Page 8
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3-3. Rating Label For CE Products
226 534-B
3-4. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-
plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
OM-222 166 Page 9
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3-5. Symbols And Definitions
. Some symbols are found only on CE products.
Amperes
Volts
Alternating Current
Circuit Protection
Duty Cycle
Output
A
IP
X
I2
V
Hz
Degree Of
Protection
Hertz
Increase
Line Connection
Load Voltage
Primary Current
Rated Current
I1
Three Phase Static
Frequency Con-
verter-Transform-
er-Frequency Con-
verter
Primary Voltage
Read Instructions
U1
U2
Rated Maximum
Supply Current
Maximum Power
Consumption
Three Phase
Percent
I1max
P
1max
Remote
Off
Panel/Local
On
High Temperature
Voltage Input
SECTION 4 − INSTALLATION
4-1. Specifications
Amperes Input at
Rated Load Output
Rated Output
Output
Required
Reflective
Inductance
50 or 60 Hz,
Three-Phase
Overall
Dimensions
Weight
Frequency
Single
Output
Dual
Output
400 V
460 V
575 V
kVA
kW
35 kW At
100% Duty
Cycle
35 kW At
100% Duty
Cycle
Length: 36-3/4 in
(993 mm)
Width: 21-1/2 in
(546 mm)
Height: 29 in
(737 mm)
5 To 30
kHz
2.5 To 50
227 lb
(103 kg)
700 A
60 A
50 A
40 A
39
37
350 A
μh
(RMS),
700 V
(RMS)
(RMS), 700
V (RMS)
Storage Temperature Range −40_ F (−40_ C) to 122_ F (50_ C)
*While idling
OM-222 166 Page 10
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4-2. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
Rating Label (Non CE Models
Only)
Use rating label to determine input
power needs. Label located under
front access door.
OR
2
6
4
Plate Label (CE Models Only)
Label located under power switch.
Location And Airflow
5
Rating Label (CE Models
Only)
Use rating label to determine input
power needs.
3
6
Line Disconnect Device
12 in
(305 mm)
Locate unit near correct input
power supply.
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in
(460 mm)
4
5
12 in
(305 mm)
18 in
(460 mm)
803 992-B
4-3. Tipping
Do not move or operate unit
where it could tip.
OM-222 166 Page 11
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4-4. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50 Hz
Three
Phase
60 Hz Three Phase
Input Voltage
400
60
460
50
575
40
Input Amperes At Rated Output
1
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
1
2
70
80
6
61
70
8
45
60
8
Circuit Breaker , Time-Delay
3
Normal Operating
4
Min Input Conductor Size In AWG
254
(77)
214
(65)
334
(102)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG
8
8
10
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended 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.
Notes
OM-222 166 Page 12
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4-5. Connecting 3-Phase Input Power For 460/575 Volt Models
!
Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
!
Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
GND/PE Earth Ground
Make input power connections to
the welding power source first.
3
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
8
. 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.
7
10
See rating label on unit and check input
voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
9
Select size and length of conductors using
Section 4-4. Conductors must comply with
national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
4
6
Welding Power Source Input Power
Connections
2
Strain Relief
Route conductors (cord) through strain re-
lief and tighten screws.
3
4
Machine Grounding Terminal
1
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
groundingterminal first.
5
Welding Power Source Line
Terminals
6
Input Conductors L1 (U), L2 (V) And
L3 (W)
Connect input conductors L1 (U), L2 (V)
and L3 (W) to welding power source line
terminals.
2
Close and secure access door on welding
power source.
Disconnect Device Input Power
Connections
7
Disconnect Device (switch shown in
OFF position)
8
Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
6
5
9
Disconnect Device Line Terminals
4
3
Connect input conductors L1 (U), L2 (V)
And L3 (W) to disconnect device line
terminals.
10 Over-Current Protection
Tools Needed:
Select type and size of over-current
connect switch shown).
3/8 in
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
803 994-C
OM-222 166 Page 13
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4-6. Connecting 3-Phase Input Power For 400/460 Volt Models
Tools Needed:
3/8 in
3
= GND/PE Earth Ground
8
10
7
L1
L2
L3
6
9
4
6
1
Ref. 804 430-A
5
2
4
3
Select size and length of conductors using Disconnect Device Input Power Connec-
Installationmust meet all National and
Local Codes − have only qualified per-
sons make this installation.
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
7
8
Disconnect Device (switch shown in
OFF position)
Disconnect and lockout/tagout input
power before connecting input con-
ductors from unit.
Welding Power Source Input Power Con-
nections
Disconnect Device (Supply) Grounding
Terminal
2
Strain Relief
!
Make input power connections to the
welding power source first.
Connect green or green/yellow grounding
conductor to disconnect device grounding ter-
minal first.
Route conductors (cord) through strain relief
and tighten screws.
Always connect green or green/yellow
conductor to supply grounding termi-
nal first, and never to a line terminal.
3
4
Machine Grounding Terminal
9
Disconnect Device Line Terminals
Green Or Green/Yellow Grounding
Conductor
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
. 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 400 or 460 VAC input
power.
10 Over-Current Protection
5
6
Welding Power Source Line Terminals
Select type and size of over-current protection
shown).
Input Conductors L1 (U), L2 (V) And L3
(W)
See rating label on unit and check input volt-
age available at site.
Connect input conductors L1 (U), L2 (V) and
L3 (W) to welding power source line terminals.
Close and secure door on line disconnect de-
1
Input Power Conductors (Customer
Supplied Cord)
Close and secure access door on welding vice. Remove lockout/tagout device, and
power source.
place switch in the On position.
OM-222 166 Page 14
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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
1
Single Air-Cooled
Output Connection
Single Liquid-Cooled
Output Connection
5
5
2
1
2
1
5
4
3
3
Ref. 803 993-C / Ref. 804 217-A
1
2
3
4
5
Output Connector 1
Output Connector 2
Protective Plug
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
Connector 2. Connect Protective Plug to
remainingOutput Connector.
1
or Output
Air-Cooled Extension Cable
Dual Liquid-Cooled Output Connection
Liquid-Cooled Extension Cable
Connect liquid-cooled output extension
cables to Output Connector 1 and Output
Connector 2.
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
Single Liquid-Cooled Output Connection
Connect liquid-cooled output extension
cable to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remainingOutput Connector.
. Extension cables must be the same
length: 25 ft (7.6 m) or 50 ft (15.2 m).
OM-222 166 Page 15
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4-8. Remote 14 Receptacle RC14 Information and Connections
1
2
3
4
Plug
ThreadedCollar
Keyway
Remote 14 Receptacle RC14
3
To connect to receptacle, align key-
way, insert plug and tighten
threaded collar.
A
J
4
K
I
B
C
L
2
1
N
H
M
D
G
F
E
2
1
803 993-C
4-9. Remote 14 Socket Information
Socket
Socket Information
+24 volts dc.
A
B
Remote Contactor
Contact closure to A completes 24 volts dc contactor control circuit.
Command reference; +10 volts dc.
Control circuit common.
C
D
E
G
Remote Output Control
Power Source Limit
Input command signal (potentiometer wiper or 0 to +10 volts dc).
Not used.
Absence of internal contact closure between F and J signals power source error to remote
control device.
F, J
Not used.
H
I
Actual frequency output signal (1 volt/10 kHz).
Average power output signal (1 volt/10 kW).
Voltage output signal RMS (1 volt/100 volts).
Total current output signal RMS (1 volt/100 amperes).
Chassis common.
L
Remote Metering
M
N
K
OM-222 166 Page 16
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4-10. Temperature Recorder Receptacle RC9 Information And Connections
1
2
3
Plug
ThreadedCollar
Temperature Recorder
Receptacle RC9 (See Section
To connect to receptacle, insert
plug and tighten threaded collar.
3
2
1
2
1
803 993-C
4-11. Temperature Recorder Socket Information
Socket No.
Socket Information
1
2
Thermocouple No. 1 (TC1), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
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
11
12
13
14
Chassis Ground
Unused
Unused
Unused
Unused
OM-222 166 Page 17
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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 insula-
tion protection from a short in the
output circuit.
For single output, only one
ground lead is required. For dual
output , use both ground leads.
1
2
Receptacles
Plug
To connect plug, align key with key-
way, insert end into receptacle, and
rotate plug until tight.
3
4
Handle
Magnet
. The secondary isolation magnet
must be in contact with bare
metal (free from rust, paint,
grease, etc.).
5
Workpiece
Use handle to place magnet on the
workpiece.
1
2
3
5
4
803 994-B / Ref. 801 826-C / Ref. 801 828-C
OM-222 166 Page 18
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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. Maxi-
mum output from receptacle is 2.5
amperes.
1
CB1 protects 115 volt receptacle
RC1 from overload. If CB1 opens,
RC1 does not work.
2
1
2
803 993-C
4-14. Locating Thermocouples
Thermocouplelocation 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
S
S
The code normally specifies the number of thermocouples to be used based on the pipe diameter.
The control thermocouple is placed in the plane of the weld (center of the heat zone).
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.
4.
5.
6.
Attach a spare thermocouple beside control thermocouples.
Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces.
Physically inspect all thermocouples for continuity and mark them by an identification number corresponding to the recorder channel.
Match the drawings of the workpiece indicating the numerous thermocouple locations, controlling thermocouple locations, etc. to weld identifi-
cation information.
7.
The system is equipped with 3-pin thermocouple connections at the front of the unit. Six thermocouples can be attached to the power source.
S
The system is equipped with 3-pin connectors to accommodate shielded extension cables. The shielded
cables protect from electrical interference.
8.
Type K thermocouple wire has a positive and negative wire. The positive wire is marked as solid yellow or striped yellow. The connector screw
terminals are marked positive and negative. Be sure to attach the wire to the connector with proper polarity.
OM-222 166 Page 19
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9.
The following describes the thermocouple routing from work to power source.
S
Type K thermocouple wire (two wire) is attached directly to the workpiece using a
Thermocouple Attachment Unit (see next section for information on attaching thermocouples).
S
S
The other end is fitted with a 2-pin type K connector.
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
S
The extension cable contains six, 3-wire bundles of shielded cable.
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.
3
4
Individual Thermocouple Extension
Cable
. Do NOT weld thermocouples to work-
piece while thermocouple cable is con-
nected to the power source.
Multiple Thermocouple Extension
Cable
Turn Off power source.
1
2
Power Source
Align plug pin(s) with receptacle socket(s)
and push plug into receptacle.
To connect thermocouples to the power
source, proceed as follows:
Thermocouple Receptacles
804 320-A
OM-222 166 Page 20
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4-15. Attaching Welded Thermocouples
. Do NOT weld thermocouples while connected to power source.
1.
Attach thermocouples using a portable Thermocouple Attachment Unit (TAU). This unit spot welds thermocouple wire directly to the
workpiece. This method of thermocouple attachment ensures accurate temperature measurement.
2.
3.
4.
5.
6.
Clean (file or grind) any loose scale or rust from the workpiece at the places where the wires will be attached.
Clean the location for the lead magnet to minimize resistance. Place the magnet as near to the thermocouple positions as possible.
Strip 1/4 inch of insulation from the thermocouple wires.
Set the output variable control of the TAU to about eighty percent (80%).
Grasp one of the stripped wires with the tip of the jaws of the application pliers.
. Don’t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit. This will cause
the thermocouple wire to fuse to the pliers, rather than the workpiece.
7.
Press the end of the wire to the workpiece at ninety degrees to the surface, and maintain a firm pressure. Make sure the Thermocouple Attach-
ment Unit is charged and wait for the ready light to glow.
8.
9.
Press discharge button, and the wire should weld to the workpiece. There will be a sharp crack and a slight arc flash.
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
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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
temperaturesensor* can be used. This eliminates the need to weld thermocouples and the sensor can be moved during the preheat process to check
temperaturesat other locations on the joint.
. Removing the contact probe will display a short duration of heat drop on the temperature recorder, if used.
The contact temperature sensor can be plugged into the thermocouple extension cable or a Type K 25 ft. armored extension cable* can be used. One of
these extensions is required for each sensor.
In preheating applications, the thermocouple must be placed under the induction coil. Temperatures at the weld joint can be checked with temperature
sensitive crayons to verify the preheat temperature.
Welded thermocouples are normally used in stress relieving applications due to their accuracy.
*See product literature for item part number.
4-17. Placing Temperature Probe
1
2
Blanket
TemperatureProbe
Place temperature probe between
blanket and metal material. The
probe must be in contact with the
materialbeing 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
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SECTION 5 − COMPONENTS AND CONTROLS
5-1. Controls
3
4
5 6 7 10
9
8
11
18
16
17
2
15
14
13
12
19
1
803 995-B
LED lights to indicate a system limit condi-
tion.
14 ParameterButton
. When a control panel button is pushed
the yellow lamp lights to indicate ac-
tivation.
Use button to display real time power
source operating parameters.
7
Heat On LED
LED lights to indicate the power source out-
put is energized.
1
Power Switch
15 Cooler Button
Use switch to turn power source On and
Off.
Use button to turn cooler On and Off.
16 Increase Button
8
Stop Button
Use button to stop a heating process.
Hold Button
2
TC1−4 Temperature Display
9
Use button to increase values in set-up
screen.
Provides temperature display of thermo-
couples 1 through 4.
Use button to hold a heating process.
10 Run Button
17 Decrease Button
3
Control Thermocouple LED’s
Use button to run a heating process.
11 Cursor Button
Use button to decrease value in program
screen.
LED’s indicate which thermocouples (1−4)
are used to control the heating process.
4
Temperature Units LED’s
18 4 x 40 LCD Display
Use button to move selection cursor in the
LED’s indicate units for temperature mea-
surements (°F or ° C).
Displays programming, runs status, pa-
rameter, fault and limit conditions, and trou-
bleshootingguide.
12 Program Button
5
Fault LED
Use button to program the process control.
13 Run Status Button
19 Thermocouple Input Receptacles
LED lights to indicate a system fault condi-
tion.
Use button to display real time operating
status.
Use receptacles for type K thermocouple
inputs.
6
Limit LED
OM-222 166 Page 23
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SECTION 6 − SETUP AND OPERATION
6-1. Safety Equipment
Wear
the
following
during
1
2
operation:
1
2
Dry, Insulating Gloves
Safety Glasses With Side
Shields
DO NOT wear rings or watches
during operation.
sb3.1* 1/94
6-2. System Description
The ProHeat 35 Induction Heating Power Source is designed to function either as an air-cooled system or a liquid-cooled system. Depending on the
system type (either air-cooled or liquid-cooled), the power source is automatically configured to operate and provide an output appropriate for the type
of connected heating device.
A special identifier, embedded within the extension cable connector, provides the means for the power source to configure itself by recognizing the type
of extension cable(s) attached to its output connectors.
Designed to provide a single level of output (up to 35 kW), the ProHeat 35 power source has two panel mounted connectors that are connected in
parallelto 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
The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal tempera-
6-3. Power Source/System Setup
kW
A
Hz
To view the System Setup screen, simultaneously press the Parameters
on the display:
and Program
buttons and the following screen will appear
V
System Setup Screen
Degree Units: >_F
Tolerance...: 25
SYSTEM SETUP
Backlight: Yes
Input Type..: K TC Control Mode: Manual
Power Output: 35 KW System Lock: No
To change a setting:
S
S
Press the Cursor
button to move the cursor to the parameter to be changed
Press Increase
or Decrease
button to select desired set-up feature.
OM-222 166 Page 24
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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
or Decrease
or Decrease
or Decrease
button to select the desired temperature tolerance.
button to turn LCD display backlight On or Off.
button to select the desired temperature input
S
The factory default is 25 °F.
Backlight − press the Increase
S
The factory default is On.
Input Type − press the Increase
device.
S
The factory default and only selection is K TC.
Control Mode − press the Increase
or Decrease
button to select the desired method of system
control, either Temperature or Manual. For more details about methods of control, see Section
6-4.
S
The factory default is temperature based control.
Power Output − press the Increase
or Decrease
button to adjust the maximum power source
output.
S
The factory default is 35 kW.
System Lock − press the Increase
or Decrease
button to lock or unlock the operator interface to
prevent tampering with any programs. Yes indicates the system is locked, and No indicates the
system is unlocked.
S
The factory default is No (unlocked).
. All parameters in System Setup are considered global, and any changes to the system set-up parameters will apply to all programs.
OM-222 166 Page 25
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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
and Decrease
buttons, and press the Program
button.
6-4. Programming
Programmingallows 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-basedcontrol operates the system and controls the heating process based on temperature feedback from thermocouple inputs. Ther-
mocouples must be used for this mode of operation or the system will not operate. Within the temperature-based mode there are four different
processes available as follows: Preheat, Bakeout, PWHT (Post-Weld Heat Treat), and Custom Program.
Press the Program button to access the programming mode. Use the cursor button to move the cursor to the desired temperature-based process,
then press the Program button again to select the process.
6-4-1-1. Preheat
The preheat process is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time.
When this process is selected, the following screen will appear on the LCD display:
Preheat Screen
Mode.......: Preheat
Control TC.: 1
Temperature: 400
Soak Time..: 01:00:00
The default position of the cursor is next to Control TC. Press the Increase
or Decrease
button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor
Decrease
button to move the cursor to the desired selection (Temperature or Soak Time), and press the Increase
button to change the value to the desired setting.
or
. The minimum and maximum temperature settings for preheat are 0 and 10005 F (−18 and 5385 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 4005 F (2045 C). If the program setting
is above 4005 F (2045 C), the following screen will appear on the LCD display when the Run button is pressed:
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
OM-222 166 Page 26
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6-4-1-2. Bake-Out
The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from bake-out if desired. When this
process is selected, the following screen appears on the display:
Bake-Out Screen
Mode......: Bake−Out
Control TC:>1
Soak Temp.: 600 Soak Time: 01:00:00
Cool Temp.: 200 Cool Rate: 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.
. The minimum and maximum soak temperature settings for bake-out are 0 and 10005 F(−18 and 5385 C). The minimum and maximum soak times
are 0 and 1000 hours. The minimum and maximum cool rates are 10 and 9999 5/hr. When the system is utilizing air-cooled blankets, the maximum
temperaturesetting is 4005 F(2045 C). If the program setting is above 4005 F (2045 C), the following screen will appear on the LCD display when
the Run button is pressed:
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
6-4-1-3. PWHT (Post-Weld Heat Treat)
The post-weld heat treat process allows the operator to program a post-weld heat treat where ramp temperature (on increase and decrease) and
ramp rates are the same. When this process is selected, the following screen appears on the display:
PWHT Screen
Mode......: PWHT
Control TC:>1,2
Ramp Temp.: 200 Ramp Rate: 600 _/Hr
Soak Temp.: 400 Soak Time: 01:00:00
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The default position of the cursor is next to Control TC. Press the Increase
or Decrease
button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor
button to move the cursor to the desired selection (Ramp Temperature, Ramp Rate, Soak Temperature, or Soak Time),
and press the Increase
or Decrease
button to change the value to the desired setting.
Soak Time
Soak Temp
Ramp Rate
Ramp Temp
Figure 6-1. Soak Parameters
. The minimum and maximum ramp temperature settings for PWHT are 0 and 14505 F (−18 and 7885 C). The minimum and maximum ramp rates
are 10 and 99995 F/hr (6 and 55555 C/hr). The minimum and maximum soak temperatures are 0 and 14505 F (−18 and 788 5 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 4005 F (204
5
C). If the program setting is above 4005 F (2045 C), the following screen will appear on the LCD display when the Run button is pressed.
Maximum Temperature Message Screen
Cannot enter Run mode
Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
6-4-1-4. Custom Program
In Custom Program, the operator can create a custom program with multiple steps or nonsymmetrical heat treat programs where the heating and
cooling rates and temperatures are different. When this process is selected, the following screen appears on the display:
. This is the screen for initial use of the system. Subsequent use of custom program will revert to the last program used.
OM-222 166 Page 28
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Custom Program Screen
Mode.......: Custom Program
Segment....: 1
Type.......: End
Control TC.: 1
The default position of the cursor is next to Segment. Press the Increase
or Decrease
button to increase or decrease the
segment number, unless the segment type is End. In this case, the segment number will advance to segment 1.
Use the Cursor
button to move the cursor to the desired selection (Type or Control TC), and press the Increase
or Decrease
or
button to change the value to the desired setting. When the cursor is moved to the Type selection, pressing the Increase
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.
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: 600
Use the Cursor
button to move the cursor to the Temperature position and the initial temperature can be adjusted using the Increase
button.
or Decrease
Pressing the Cursor
button again automatically advances the program to the next segment number.
Ramp Function
When type is set to Ramp, the following screen appears on the display:
OM-222 166 Page 29
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Custom Program Screen
Mode.......: Custom Program
Segment....: 1
Type.......: Ramp
Temperature: 600 Ramp Rate: 600 _/Hr
Use the Cursor
button to move the cursor to the Temperature or Ramp Rate position and use the Increase
or Decrease
button to set the desired value.
When the cursor is in the Ramp Rate position, pressing the Cursor
number.
button again automatically advances the program to the next segment
Notes
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Soak Function
When type is set to Soak, the following screen appears on the display:
Custom Program Screen
Mode.......: Custom Program
Segment....: 1
Type.......:>Soak
Soak Time..: 00:01:00
Use the Cursor
button to move the cursor to the Soak Time position and use the Increase
or Decrease
button to set
the desired value.
When the cursor is in the Soak Time position, pressing the Cursor
button again automatically advances the program to the next segment
number.
End Function
When type is set to End, the following screen appears on the display:
Custom Program Screen
Mode.......: Custom Program
Segment....:> 2
Type.......: End
Control TC.: 1
The only changeable parameter in the End segment is selecting the number of thermocouples. Use the Cursor
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.
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Typical 5-Segment Custom Program
Custom Program Screen
Mode.......: Custom Program
Segment....: 1
Type.......:>Step
Temperature: 600
Temperatureincreases to 600 degrees at full-programmed power.
Custom Program Screen
Mode.......: Custom Program
Segment....: 2
Type.......: Ramp
Temperature:>1250 Ramp Rate: 600 _/Hr
Controlledheating to 1250 degrees F at a ramp of 600 degrees per hour.
Custom Program Screen
Mode.......: Custom Program
Segment....: 3
Type.......: Soak
Soak Time..:>01:00:00
Soak at 1250 degrees F for a period of 1:00.
Custom Program Screen
Mode.......: Custom Program
Segment....: 4
Type.......:>Ramp
Temperature: 600 Ramp Rate: 600 _/Hr
Controlledcooling to 600 degrees F at a rate of 600 degrees per hour.
Custom Program Screen
Mode.......: Custom Program
Segment....: 5
Type.......: End
Control TC.: 1
End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.
6-4-2. Manual Control
Manualcontrol 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:
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Manual Program Screen
Mode....: Manual
Power..: 0.0 KW
Current: 0 A
Command.: 0.0 KW
Run Time: 00:03:00
Voltage: 0 V
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
and Decrease
buttons, and press the Program
button.
6-5. Run Status
Run status allows the operator to check status of a program during in-process heating. Depending on the control mode (Temperature or Manual) and
the temperature based mode (Preheat, Bake-Out, PWHT, or Custom), different style screens appear on the display. Run status is for monitoring
purposes only and has no selectable or changeable parameters.
6-5-1. Temperature Based Control
6-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen
Run Status Screen
Mode.......: Preheat
Target Temp: −−−−
TC5: 77
TC6: 77
Countdown..: −−:−−:−−
Status.....: Stopped
Mode displays the programming mode (Preheat, Bake-Out, PWHT, or Custom Program). During active operation, Target Temp shows the target
temperaturebased on the specific program, Countdown shows the time remaining in a soak segment, and Status shows the program segment type
(step, soak, ramp, hold, or stopped). TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.
6-5-1-2. Custom Program
Run Status Screen
Mode.......: Custom Program TC5: 77
Target Temp: −−−−
TC6: 77
Countdown..: −−:−−:−−
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.
OM-222 166 Page 33
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6-5-2. Manual Control
Mode.....: Manual
Run Status Screen
TC5: 77
TC6: 77
Power....: 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
monitoringpurposes only.
. No changes can be made to the run status screen, and the Cursor, Increase and Decrease buttons are not functional.
6-6. Parameters
During active operation, the Parameters screen allows the operator to monitor the power source output operating parameters. These parameters in-
clude 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..: 0 A
Voltage..: 0 V
Frequency: 4.5 KHz
TC5: 77
TC6: 77
6-7. Cooler
The Cooler
button is used to turn the cooler On or Off on systems using liquid-cooled output cables. Systems using liquid-cooled output
cables will not deliver output unless the cooler is On. If the cooler is not started prior to initiating a heating cycle, the system will automatically start the
cooler when the Run
button is pressed. Pressing the Stop
button.
button does not shut off the cooler. The cooler must be shut off separately
by pressing the Cooler
When power source output is energized, the cooler cannot be turned off. If the Cooler
button is pressed while output is energized, the follow-
ing screen will appear on the display:
Cooler Message Screen
Cooler cannot be turned off
while output is on
OM-222 166 Page 34
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. 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
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
S
The Stop
button indicator LED illuminates to indicate no heating cycle is in process.
The temperature displays indicate actual temperature from the TC’s (thermocouples). If no thermocouples
are connected, the displays indicate OPEN.
S
S
Control LED’s illuminate to indicate the number of control TC’s in the last program.
The appropriate degree units (°F or °C) light illuminates.
S
The display defaults to the Run Status screen from the last program used and the Run Status
button indicator LED illuminates.
S
If no fault or limit conditions are present, system status lights are not illuminated.
button will initiate a heating cycle. When a
program run is initiated, the Run
button yellow indicator LED illuminates and the Heat On blue indicator LED illuminates to indicate output is
present to the coil. The cycle will continue until the end of the program is reached or the Stop
button is pressed.
The system has a hold function that will maintain a temperature or hold the soak time of any active temperature controlled program. Pressing the Hold
button will only activate the hold function while in the run mode. If the system is not in the run mode, the following screen will appear on the
display:
Hold Message Screen
Must be running to enter Hold mode
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In addition, when running in Manual operating mode, the Hold
button is not functional. If the system is running in Manual operating mode,
pressing the Hold
button will cause the following screen to appear on the display:
Hold Message Screen
Hold mode not available when
temperature control is not active
Pressing the Hold
button will activate the hold function while running a temperature controlled program. While in the hold mode, the parame-
ters for the program in process can be modified. The cycle will continue after pressing the Run
button. A change of program parameters
during the hold will not change the original program. The original program parameters are maintained for the next heating cycle.
To make changes to a program while in run mode, press the Hold
button and the yellow indicator LED will illuminate, and the Run
button yellow indicator LED will turn off. When in hold, the system will maintain the actual temperature of the hottest thermocouple while the program is
being changed.
S
Press the Program
button and the yellow indicator LED will illuminate. The display will change to
show the current mode of operation or the current segment of a Custom Program.
S
S
Use the Cursor
Press the Increase
Press the Run
button to move the cursor to the parameter that will be changed.
or Decrease
button to make desired changes.
S
button to resume program operation and the yellow indicator LED will illuminate, and
the Hold
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 num-
ber can be changed; however, if the operation of a segment has already been completed in a program, the change to that segment will not affect the
program function.
S
Press the Stop
button to end the program.
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6-9. System Operating Characteristics
The power source delivers a high-frequency alternating current output that energizes the coil creating the magnetic field used to heat the workpiece.
The power source output characteristics are a function of the configuration, type and number of coils used as shown in the following table:
Table 6-1. Power Source Output Characteristics
Output Type
Maximum Amperage
Maximum Voltage
Frequency Range
250 A per output for 15 minutes.
After 15 minutes, power steps
down to limit current to 150 am-
peres per output for continuous
operation.
700 V
5 − 25.7 kHz
Air Cooled Single and Dual
See Note 1
350 A
700 V
700 V
700 V
700 V
700 V
25.7 − 30 kHz
5 − 20 kHz
Single Liquid Cooled
Dual Liquid Cooled
See Note 2
20 − 30 kHz
5 − 20 kHz
350 A per output/700 A total
See Note 2
20 − 30 kHz
300
250
200
. Note 1: In the frequency range
Air Cooled Output
of 25.7 to 30 KHz, the maxi-
mum output amperage de-
creases linearly from 250 down
to 175 amperes per output. Re-
gardless of frequency, after 15
minutes the maximum output is
reduced to 150 amperes per
output.
150
100
50
0
5
25.7
30
Frequency (KHz)
400
. Note 2: In the frequency range
of 20 to 30 KHz, the maximum
output decreases linearly from
350 down to 175 amperes per
output.
Liquid Cooled Output
350
300
250
200
150
100
50
0
5
20
30
Frequency (KHz)
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SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
n = Check
Z = Change
~ = Clean
l = Replace
Reference
* To be done by Factory Authorized Service Agent
Every
3
Months
2
2
1
1
l Damaged or Unreadable ~ Output Connector Con-
~ Ground Sense Lead Re- ~ Operator Interface Over-
ceptacles lay
Labels
tacts
2
1
n Integrity Of Protective
Plug, Replace If Necessary
nlCracked Cables
Every
6
Months
~ Inside Unit
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SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.
8-1. Symbol Usage
OM-222166J - 2007−06, safety_ihtm 2007−04
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
. Indicates special instructions.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
8-2. Servicing Hazards
FLYING METAL or DIRT can injure eyes.
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.
D
D
Wear safety glasses with side shields or face
shield during servicing.
Be careful not to short metal tools, parts, or
wires together during testing and servicing.
Only qualified persons should service, test, maintain, and re-
pair this unit.
During servicing, keep everybody, especially children, away.
HOT PARTS can cause severe burns.
ELECTRIC SHOCK can kill.
D
D
Do not touch hot parts bare handed.
Do not touch or handle induction head/coil
during operation.
Keep metal jewelry and other metal personal
items away from head/coil during operation.
D
D
Do not touch live electrical parts.
Turn Off induction heating power source and
disconnect and lockout input power using line
D
disconnect switch, circuit breakers, or by removing plug from recep-
tacle, or stop engine before servicing unless the procedure specifi-
cally requires an energized unit.
D
D
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
D
Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
D
D
Do not leave live unit unattended.
EXPLODING PARTS can cause injury.
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
Failedparts can explode or cause other parts to
explode when power is applied to inverters.
D
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Always wear a face shield and long sleeves
when servicing inverters.
Disconnect input power conductors from deenergized supply line
BEFORE moving an induction heating power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
SHOCK HAZARD from testing.
D
Turn Off induction heating power source be-
fore making or changing meter lead connec-
tions.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section be-
fore touching any parts.
D
D
Use at least one meter lead that has a self-
retainingspring clip such as an alligator clip.
Read instructions for test equipment.
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.
FALLING UNIT can cause injury.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
FIRE OR EXPLOSION hazard.
D
Do not place unit on, over, or near combustible
surfaces.
D
Do not service unit near flammables.
OM-222 166 Page 39
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H.F. RADIATION can cause interference.
MOVING PARTS can cause injury.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D
D
Keep away from moving parts such as fans.
Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D
D
D
Keep hands, hair, loose clothing, and tools away from moving
parts.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
If notified by the FCC about interference, stop using the
equipmentat once.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
READ INSTRUCTIONS.
OVERUSE can cause OVERHEATING.
D
D
D
Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Consult the Owner’s Manual for induction heat-
ing safety precautions.
Use only genuine replacement parts from the
manufacturer.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before us-
ing induction heating equipment again.
D
Do not block or filter airflow to unit.
8-3. California Proposition 65 Warnings
For Gasoline Engines:
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.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
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
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
8-4. EMF Information
ConsiderationsAbout Induction Heating And The Effects Of Low Fre-
quency Electric And Magnetic Fields
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Induction heating current, as it flows through induction heating cables,
will cause electromagnetic fields. There has been and still is some
concern about such fields. However, after examining more than 500
studies spanning 17 years of research, a special blue ribbon committee
of the National Research Council concluded that: “The body of
evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human-
health hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when using induction heating equipment.
4. Keep induction heating power source and cables as far away
from operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
OM-222 166 Page 40
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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
troubleshootingcapability consists of the Fault LED, Limit LED, and message screens that appear on the front panel LCD display.
9-1. Operator Interface Indicators
2
1
3
803 995-B
1
Fault LED
2
Limit LED
3
4 x 40 LCD Display
Displays programming, run status, param-
eters, fault and limit conditions, and
troubleshootingguide.
LED lights to indicate a system fault
condition.
LED lights to indicate a system limit
condition.
OM-222 166 Page 41
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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
S
Acknowledge the limit and continue operation.
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
kW
A
Hz
button, or Parameters
button is pressed.
V
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
LCD display will indicate possible solutions based on the type of limit condition.
button, and the
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 condi-
tion, press the Stop button. After changes are made to the setup, press the Run button to restart the process.
9-3. Limit Condition Codes
Limit Condition
Additional Information
L01: Thermocouple #1 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
L02: Themocouple #2 Open
L03: Thermocouple #3 Open
L04: Thermocouple #4 Open
L05: Thermocouple #5 Open
L06: Thermocouple #6 Open
Check for open temperature sensor and repair
Change to back-up temperature sensor
Check for open temperature sensor and repair
Change to back-up temperature sensor
Check for open temperature sensor and repair
Change to back-up temperature sensor
Check for open temperature sensor and repair
Change to back-up temperature sensor
Check for open temperature sensor and repair
Change to back-up temperature sensor
L07: Output Voltage Limit
L08: Output Voltage Limit
Tighten blanket against pipe surface
Increase number of turns
Increase coil space
Shorten extension cable
Increase insulation width
L09: Output Current Limit
L10: Output Current Limit
Tighten blanket against pipe surface
Increase number of turns
Decrease coil space
Tighten cable on insulation
OM-222 166 Page 42
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Limit Condition
Additional Information
L11: Coolant Overtemp Limit
Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
L12: Power Source Overtemp Limit
L13:Cable Connection
Check for blocked vents
Clean wind tunnel heat sinks
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
problemwith 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 button to display the fault condition.
Pressing the Decrease
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
F51: Thermocouple #1 Internal Fault
F52: Themocouple #2 Internal Fault
F53: Thermocouple #3 Internal Fault
F54: Thermocouple #4 Internal Fault
F55: Thermocouple #5 Internal Fault
F56: Thermocouple #6 Internal Fault
F57: CJT Sensor Internal Fault
F58: Output Voltage Fault
Additional Information
Service required
Service required
Service required
Service required
Service required
Service required
Service required
Service required
Service required
F59: Output Current Fault
F60: Temperature Sensor Fault
Check control TC connections
Check control TC extension cable
F61: Coolant Flow Fault
F62: Isolation Fault
Check for coolant leak
Clean for coolant blockage
Check coolant filter and level
Check coolant connections
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
F66: Under Frequency Fault
Service required
Check for loose or open connections
in output cable
Decrease number of turns
Decrease coil space
OM-222 166 Page 43
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Fault Condition
F67: Over Frequency Fault
Additional Information
Verify heating cable properly wrapped
Verify material being heated is magnetic
F68: Cable Connection Fault
F69: Coolant Overtemp Fault
Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
F70: Internal Communication Fault
F71: Internal Thermistor Fault
Service required
Service required
F72: Coolant Thermistor Fault
F73: Decoupled/Open Coil
Service required
Service required
F74: Isolation Fault Self-Test Error
F75: Internal Power Supply Fault
F76: Current Source Control Fault
F77: Power Source Internal Comm Fault
F78:Output Current Sense Fault
Service required
Service required
Service required
Service required
Check for loose/open output connection
9-6. System Diagnostic Screens
Additionalsystem diagnostics are available and accessible through the operator interface. Detail operational parameters can be accessed by pressing
kW
A
Hz
and holding the Run Status
button and pressing the Parameters
button.
V
When this feature is initially activated, the following screen appears on the LCD display:
System Diagnostic Screen
RemCmd: 1023 Off
OutI1: 0 A
OutI2: 0 A
IsrcFb: 0 A
Cable1: LQD DIAG1
Cable2: LQD
ClntFR: 0.75 GPM
ClrSts: Flowing
RemCmd − This is the value of the remote command and the status of the remote contactor.
. Remote controls can be used to enable/disable output. They do not affect output power level.
Out I1 − This is the value of the output current on output 1.
Out I2 − This is the value of the output current on output 2.
Isrc FB − This is the value of the amperage in the current source inverter.
Cable 1 − This is the cable type hooked up to output number one. Possible labels:
S
S
S
S
AIR − for an air-cooled cable
LQD − for a liquid-cooled cable
PLUG − for a protective plug
OPEN − no cable or plug in place
Cable 2 − This is the cable type hooked up to output number two. Possible labels:
S
S
S
AIR − for an air-cooled cable
LQD − for a liquid-cooled cable
PLUG − for a protective plug
OM-222 166 Page 44
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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
S
Off
Flowing
kW
V
A
Hz
The second diagnostic screen is available by again pressing and holding the Run Status
button and pressing the Parameters
button.
System Diagnostic Screen
VLnA−B: 460V Therm1: 75
DIAG2
VLnB−C: 460V Therm2: 75 Therm5: OPEN
VLnC−A: 460V Therm3: 75 ClrTmp: 77
VBus: 650V Therm4: OPEN RmtFlw: Off
VLnA-B − This is the phase to phase line voltage between phases A and B.
VLnB-C − This is the phase to phase line voltage between phases B and C.
VLnC-A − This is the phase to phase line voltage between phases C and A.
VBus − This is the DC bus voltage.
Therm1 − This is the temperature of the current source primary heatsink.
Therm2 − This is the temperature of the bridge heatsink.
Therm3 − This the the temperature of the current source secondary heatsink.
Therm4 − Open (not used).
Therm5 − Open (not used).
ClrTmp − This is the temperature of the coolant on a liquid-cooled system.
S
OPEN − no cooler is detected.
RmtFlw − This is the status of the relay contacts for remote coolant flow on a liquid-cooled system.
S
S
OFF
ON
. RmtFlw feature is unsupported on the current platform.
OM-222 166 Page 45
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9-7. Removing Wrapper and Measuring Input Capacitor Voltage
!
900 Volts dc can be present
on the capacitor bus and
significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage on inverter assembly
as shown to be sure the input
capacitors have discharged
before working on unit.
Tools Needed:
5/16, 3/8 in
!
Turn Off welding power
source, and disconnect
input power.
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
Remove right side panel and dis-
connect fan motor FM3.
1
Current Source Interconnect
Board PC4
2
Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC4 as shown until voltage drops to
near 0 (zero) volts.
. If the capacitor voltage does
not drop to near zero after
several minutes, use a bleeder
resistor of between 200 and
500 ohms, at least 10 watts,
and #16 AWG 600 volts ac in-
sulation rated wire to discharge
the capacitor(s).
1
3
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit. Re-
connect FM3 and reinstall right side
panel when finished.
+ lead to right bus terminal,
− lead to left bus terminal
3
Typical Bleeder Resistor
200 to 500 ohm, 10 watt
wire wound resistor
2
#16 AWG 600 Volts AC
Insulation Rating
804 519-B
OM-222 166 Page 46
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9-8. Blowing Out Inside Of Unit
!
!
Turn Off welding power
source and disconnect input
power.
Remove wrapper and be
sure input capacitors are
discharged.
Blow out inside of unit. Blow out fan
motors in right side panel and front
panel.
804 625-B
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-222 166 Page 47
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218 057-G
OM-222 166 Page 49
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SECTION 11 − PARTS LIST
3
. Hardware is common and
5
not available unless listed.
4
12
See Figure
11-3
13
14
15
10
9
1
7
11
6
8
See Figure
11-2
11
2
804 218-D
Figure 11-1. Wrappers
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Wrappers
. . . 1 . . . . . . . . . . . . +217 470 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 217 860 . . LABEL, warning electric shock and input pwr (FR) . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +217 325 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 147 876 . . LABEL, warning general precautionary induction heat . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 217 334 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 217 468 . . DOOR, primary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 189 491 . . SPACER, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 168 343 . . HINGE, cont polyolefin copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 222 106 . . BRACKET, mtg fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . FM3 . . . . . 236 263 . . FAN, muffin 24VDC 3000 RPM 130 CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 206 270 . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 198 035 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 197 931 . . MAGNET, permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 197 900 . . CABLE, work ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 127 836 . . PLUG, tw lk insul male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC2 . . . . . 135 635 . . HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . . . . 131 054 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG61 . . . 131 204 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG63 . . . . 115 094 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 50
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1
5
. Hardware is common and
4
not available unless listed.
8
13
12
11
3
2
6
7
9
10
804 219-A
Figure 11-2. Front Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Front Panel
. . . 1 . . . . . . . . . . . . . 217 323 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 216 225 . . NAMEPLATE, ProHeat 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 216 224 . . PANEL, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . TC1−TC6 . . 218 686 . . RECEPTACLE ASSY, thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 5 . . . . . . . . . . . . . 217 327 . . PLATE, TC receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . S1 . . . . . 213 060 . . SWITCH, tgl 3pst 60 A 600 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 212 810 . . LABEL, on−off w/symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 221 493 . . LABEL, TC 1−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 115 440 . . STANDOFF, no 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . 10 . . . . . . . . . . . . . 224 143 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . PC8 . . . . . 216 068 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . PC2 . . . . . 216 072 . . CIRCUIT CARD ASSY, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 148 297 . . NUT, 006−32 .31 hex .20 stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG24 . . . . 115 091 . . 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 51
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12
13
. Hardware is common and
not available unless listed.
5
10
9
14
1
7
2
4
6
3
8
804 220-A
11
Figure 11-3. Rear Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 11-3. Rear Panel
Quantity
. . . 1 . . . . . . . . . . . . . 217 324 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . RC1 . . . . . 174 207 . . RECEPTACLE, str dx grd 2P 3W 15 A 125 V . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 127 837 . . RECEPTACLE, tw lk insul fem (dinse type) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . CB1 . . . . . 089 807 . . SUPPLEMENTARY PROTECTOR, man reset 1P 2.5 A 250 VAC . . . . . . 1
. . . 5 . . . . . . . . . . . . . 220 824 . . COVER, receptacle weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +218 689 . . PANEL, rear output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 602 498 . . LABEL, danger high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 010 467 . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . RC14 . . . . 143 976 . . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . RC9 . . . . . 047 636 . . HOUSING PLUG+PINS,(service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 224 989 . . RECEPTACLE ASSY, output (with leads) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 234 531 . . SHELL, w/contact pin and socket (service kit for 224 989) . . . . . . . . . . . . 0
. . . 12 . . . . . . . . . . . . . 224 042 . . CONNECTOR, circ CPC protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 170 391 . . CONNECTOR, circ MS protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 147 195 . . NUT, 375−27 .54 hex .25 H nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . RC21,22 . . . 135 635 . . HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG21,22 . . 131 054 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 52
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. Hardware is common and
14
not available unless listed.
1
4
14
12
3
6
2
5
10
13
7
3
6
9
16
15
8
804 221-D
Figure 11-4. Base w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Base w/Components
. . . 1 . . . . . . . . . . . . . 217 328 . . FRAME, lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 213 865 . . BASE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 213 939 . . LABEL, warning electric shock can kill significant . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . L1,L2 . . . . 218 692 . . INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . 216 815 . . BRACKET, cap support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . C1,2 . . . . 213 870 . . CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . T1 . . . . . 213 583 . . TRANSFORMER, hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . T1 . . . . . 227 065 . . TRANSFORMER, hf (400V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 216 629 . . BRACKET, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . FM1,FM2 . . 222 728 . . FAN, nuffin 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . RC4 . . . . . . 115 090 . . HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 217 992 . . BAFFLE, air bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 224 973 . . INSULATOR, lift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 603 115 . . WEATHERSTRIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . 026 627 . . GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4 . . . . . 115 094 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 226 837 . . WASHER, rubber .343 id x .875 od x .093 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . 226 838 . . INSULATOR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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. Hardware is common and
See
not available unless listed.
9
11
10
3
13
1
7
12
8
5
6
14
15
4
2
804 222-A
Figure 11-5. Top Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Top Windtunnel
. . . 1 . . . . . . . . . . . . . 218 424 . . WINDTUNNEL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 218 684 . . HEAT SINK, AC commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 025 248 . . STANDOFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . RT2 . . . . . 222 327 . . THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 083 147 . . GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 605 339 . . WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 098 691 . . STAND−OFF,NO 6−32 X .500 LG .250 hex stl m&f . . . . . . . . . . . . . . . . . 6
. . . 8 . . . . . . . . . . . . . 217 326 . . BRACKET, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 218 691 . . INSULATOR, tank cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . PC5 . . . . . 225 556 . . KIT, circuit card assy intrcnct bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . PC3 . . . . . 216 207 . . CIRCUIT CARD ASSY, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 208 591 . . SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . . 12
. . . 13 . . . . . . . . . . . . . 212 038 . . SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 14 . . . . F1 . . . . . 225 514 . . FUSE, crtg 2. amp 600 V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 225 553 . . HOLDER, fuse crtg 30 A 600 V 13/32 X 1−1/2 LG . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG32 . . . . 115 091 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG33-38,54 . 131 204 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . PLG51,57 . . . 115 093 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG58 . . . . 115 094 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 227 082 . . CHOKE, common mode (400 V model only) . . . . . . . . . . . . . . . . . . . . . . . . 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 54
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. 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 . . C3-C6 . . . . 218 685 . . CAPACITOR, popyp met film 1.5 uf 700 VAC . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 2 . . . . . . . . . . . . . 218 688 . . BUS BAR, tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . {221 419 . . SCREW, M8 −1.2 x 12 soc hd−zinc cls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
. . . 4 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID X 0.586 OD X .078T STL PLD SPLIT.312 . . . . . . 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 55
Download from Www.Somanuals.com. All Manuals Search And Download.
. Hardware is common and
not available unless listed.
20
6
1
2
19
7
5
4
8
18
16
14
17
9
3
10
11
13
15
12
804 224-E
Figure 11-7. Right Windtunnel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Right Windtunnel
. . . 1 . . . . . . . . . . . . . 216 630 . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 213 873 . . HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 213 871 . . GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 170 647 . . BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 223 120 . . BLOCK, term 115 amp 3 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 115 443 . . STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 7 . . . . . . . . . . . . . 148 743 . . LUG, univ w/scr 600V 2−14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . RT1 . . . . . 222 326 . . THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 083 147 . . GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 224 391 . . PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 605 339 . . WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
. . . 12 . . . PC4 . . . . . 228 407 . . KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 212 038 . . SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . 176 879 . . SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 15 . . . . . . . . . . . . . 228 262 . . CIRCUIT CARD ASSY, bus intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 208 591 . . SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . . 14
OM-222 166 Page 56
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Right Windtunnel (Continued)
. . . 17 . . . . . . . . . . . . . 229 728 . . STRAP, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 18 . . . . . . . . . . . . . 216 262 . . CIRCUIT CARD ASSY, cooler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 030 170 . . BUSHING, snap−in nyl .750 id x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 231 050 . . ASSY, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG64,410,
411 . . . . . . 115 093 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . PLG47 . . . . 115 091 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG45,61 . . 131 204 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG62 . . . 201 665 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG63 . . . . 115 094 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG111, 112
121, 132,
141, 142 . . . 131 054 . . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 57
Download from Www.Somanuals.com. All Manuals Search And Download.
. Hardware is common and
not available unless listed.
22
1
6
2
21
4
7
8
17
16
19
5
14
9
3
10
11
20
15
13
15
12
804 431-E
Figure 11-8. Right Windtunnel (400 V Model Only)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-8. Right Windtunnel (400 V Model Only)
. . . 1 . . . . . . . . . . . . . 216 630 . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 213 873 . . HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 213 871 . . GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 170 647 . . BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 225 356 . . CIRCUIT CARD ASSY, input filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 115 443 . . STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 7 . . . . . . . . . . . . . 148 743 . . LUG, univ w/scr 600V 2−14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . RT1 . . . . . 222 326 . . THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 083 147 . . GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 6
. . . 10 . . . . . . . . . . . . . 224 391 . . PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 605 339 . . WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
. . . 12 . . . PC4 . . . . . 228 407 . . KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 212 038 . . SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . 226 579 . . SPACER, leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 176 879 . . SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 16 . . . . . . . . . . . . . 226 041 . . BRACKET, mtg ce filter ground plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 216 262 . . CIRCUIT CARD ASSY, cooler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 228 262 . . CIRCUIT CARD ASSY, bus intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-222 166 Page 58
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-8. Right Windtunnel (400 V Model Only) (Continued)
. . . 19 . . . . . . . . . . . . . 208 591 . . SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . . 14
. . . 20 . . . . . . . . . . . . . 229 728 . . STRAP, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . 030 170 . . BUSHING, snap−in nyl .750 id x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 231 050 . . ASSY, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG64,410,
411 . . . . . . 115 093 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . PLG47 . . . . 115 091 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG45,61 . . 131 204 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG62 . . . 201 665 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG63 . . . . 115 094 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG111, 112
121, 132,
141, 142 . . . 131 054 . . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 59
Download from Www.Somanuals.com. All Manuals Search And Download.
. Hardware is common and
12
not available unless listed.
1
10
2
8
6
13
7
14
15
3
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 . . . . . . . . . . . . . 216 631 . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 218 683 . . HEAT SINK, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 170 647 . . BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . 8
. . . 5 . . . . . . . . . . . . . . 115 443 . . STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 6 . . . . . . . . . . . . . 083 147 . . GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
. . . 7 . . . RT3 . . . . . 222 327 . . THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 030 170 . . BUSHING, snap-in nyl .750 ID x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 218 430 . . COVER, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 220 825 . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . C7-C10 . . . 218 687 . . CAPACITOR, polyp film 1.35 uf 700 VAC +5% −0% . . . . . . . . . . . . . . . . . . 4
. . . 11 . C7-C10 . . . 225 775 . . CAPACITOR, polyp film 1.10 uf 700 vac +5% −0% (400 V model only)
4
. . . 12 . . . . T2 . . . . . 219 002 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PC7 . . . . . 225 558 . . KIT, circuit card assy intrcnct I srce out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PC1 . . . . . 217 928 . . CIRCUIT CARD ASSY, power source control . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 212 038 . . SCREW, M4 − .7 x 8.5 pan hd−phl stl pld slffmg . . . . . . . . . . . . . . . . . . . . . 8
OM-222 166 Page 60
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-9. Left Windtunnel (Continued)
. . . . . . . PLG16,
121,122 . . . 131 054 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . PLG19,
120 . . . . . . 115 094 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG15,
118 . . . . . . 115 093 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG77,
119 . . . . . . 115 092 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG17 . . . . 115 091 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG18,
116 . . . . . 131 056 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG13,
113 . . . . . 162 382 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG14 . . . 130 203 . . 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
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. Hardware is common and
not available unless listed.
4
3
5
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 . . . . . . . . . . . . . 221 440 . . O-RING, .737 ID x .103 CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 221 443 . . SOCKET ASSY, radsok 14 mm cable end . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 221 099 . . CLAMP, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 136 343 . . SCREW, K50 x 20 pan hd-phl stl pld pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . 224 261 . . CAP, plug assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 221 438 . . COLLAR, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 221 437 . . RETAINER, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 221 442 . . PIN, radsok 14 mm cable end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 225 919 . . SHELL ASSY, connector - protective plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-222 166 Page 62
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Notes
SOCKET/WRENCH SELECTION TABLE
(U.S. STANDARD)
SOCKET/WRENCH SELECTION TABLE
(METRIC)
Specifications
Bolt Decimal
Socket or Wrench Size
Specifications
U.S.
Socket or Wrench Size
Bolt
Bolt
Nut
Decimal
Bolt
Nut
Diameter Equivalent
Diameter
Equivalent
1/4 in
5/16 in
3/8 in
7/16 in
1/2 in
9/16 in
5/8 in
3/4 in
7/8 in
1 in
.250 in
.3125 in
.375 in
.4375 in
.500 in
.5625 in
.625 in
.750 in
.875 in
1.000 in
3/8 in
1/2 in
7/16 in
9/16 in
5/8 in
6 mm
8 mm
.2362 in
.3150 in
.3937 in
.4724 in
.5512 in
.6299 in
.7087 in
.8661 in
.9449 in
10 mm
14 mm
17 mm
19 mm
22 mm
24 mm
27 mm
32 mm
36 mm
10 mm
14 mm
17 mm
19 mm
22 mm
24 mm
27 mm
32 mm
36 mm
9/16 in
5/8 in
10 mm
12 mm
14 mm
16 mm
18 mm
22 mm
24 mm
3/4 in
3/4 in
13/16 in
7/8 in
7/8 in
15/16 in
1-1/8 in
1-5/16 in
1-1/2 in
1 in
1-1/8 in
1-5/16 in
1-1/2 in
OM-222 166 Page 63
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Notes
OM-222 166 Page 64
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
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, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
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.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
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.
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.
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
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
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.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
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.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
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.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
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.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
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
© 2007 Miller Electric Mfg. Co.2007−01
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