Miller Electric ProHeat 35 User Manual

OM-222 166K 2007−11
Processes

Induction Heating

Description

Induction Heating Power Source

ProHeat 35

Visit our website at

www.MillerWelds.com

File: Induction Heating

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Induction Heating Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 5 . . . . . .

2-4. Proposition californienne 65 Avertissements 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de sécurité 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Information EMF 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Warning Label Definitions (Continued) 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Rating Label For CE Products 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. WEEE Label (For Products Sold Within The EU) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E

20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]

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

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

ihom _2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

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

NOTICE − Indicates statements not related to personal injury.

1-2. Induction Heating Hazards

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

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever

internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard.

D Do not touch live electrical parts.
D Enclose any connecting bus bars and coolant fittings to prevent

unintentional contact.

D Wear dry, hole-free insulating gloves and body protection.
D 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 ac­cidental contact with the workpiece or ground. For these
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not
work alone!

D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

D Use only nonconductive coolant hoses with a minimum length of 18

inches (457 mm) to provide isolation.

D Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input 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.

the output is on. The input power circuit and machine

. Indicates special instructions.

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

D When making input connections, attach proper grounding

conductor first − double-check connections.

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

and sparks.

D Frequently inspect input power cord for damage or bare wiring − re-

place cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D Do not touch power circuit if you are in contact with the work, ground,

or another power circuit from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.

SIGNIFICANT DC VOLTAGE exists in inverter-type
power sources after removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before
touching any internal parts.

FUMES AND GASES can be hazardous.

Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation to re-

move fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while wearing

an air-supplied respirator. Always have a trained watchperson near­by. Fumes and gases from heating can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.

D 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.

D Do not overheat coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and while wearing an air­supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if overheated. See coating MSDS
for temperature information.

OM-222 166 Page 1

FIRE OR EXPLOSION hazard.

INDUCTION HEATING can cause burns.

D Do not overheat parts.
D Watch for fire; keep extinguisher nearby.

D Keep flammables away from work area.
D Do not locate unit on, over, or near combustible surfaces.
D Do not install unit near flammables.
D Do not operate where the atmosphere may contain flammable

dust, gas, or liquid vapors (such as gasoline).

D After completion of work, inspect area to ensure it is free of

sparks, glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Allow cooling period before handling parts or equipment.
D Keep metal jewelry and other metal personal items away from

head/coil during operation.

D Hot parts and equipment can injure.
D Do not touch or handle induction head/coil

during operation.

D Do not touch hot parts bare-handed.

1-3. Additional Symbols for Installation, Operation, and Maintenance

FALLING UNIT can cause injury.

D Use handle and have person of adequate

physical strength lift unit.

D Move unit with hand cart or similar device.

D For units without a handle, use equipment of

adequate capacity to lift unit.

D When using lift forks to move unit, be sure forks are long enough

to extend beyond opposite side of unit.

FLYING METAL OR DIRT can injure eyes.

D Wear approved safety glasses with side

shields or wear face shield.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified person familiar with electronic equipment per-

form this installation.

D The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the equip-

ment at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut.

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.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

OVERUSE can cause OVERHEATING

D Allow cooling period.

D Reduce output or reduce duty cycle before

starting to heat again.

D Follow rated duty cycle.

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine replacement parts from the

manufacturer.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-222 166 Page 2

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten­dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for Re­gion 5, Chicago, is 312-353-2220, website: www.osha.gov).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

1-6. EMF Information

Considerations About Induction Heating And The Effects Of Low Fre­quency Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields − Background Paper, OTA-
BP-E-53 (Washington, DC: U.S. Government Printing Office, May

1989): “. . . there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can in­teract with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientif­ic understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow
us to draw definite conclusions about questions of possible risk or to of-

Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario,
Canada L4W 5NS (phone: [phone] or in Toronto 416-747-4044,
website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone: [phone],
website: www.ansi.org).

fer clear science-based advice on strategies to minimize or avoid
potential risks.”

To reduce magnetic fields in the workplace, use the following proce­dures:

1. Arrange output cable to one side and away from the operator.

2. Do not coil or drape output cable around the body.

3. Keep power source and cable as far away from the operator as
practical.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If
cleared by your doctor, then following the above procedures is recom­mended.

OM-222 166 Page 3

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

ihom _2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu­rité énumérées à la section 2-5. Veuillez lire et respecter toutes
ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact de composants électriques peut provo­quer des accidents mortels ou des brûlures graves.
Le circuit électrique et les barres collectrices ou les

l’appareil fonctionne. Le circuit d’alimentation et les circuits internes
de la machine sont également sous tension lorsque l’alimentation est
sur marche. Des équipements installés ou reliés à la borne de terre de
manière incorrecte sont dangereux.

D Ne pas toucher aux pièces électriques sous tension.
D Protéger toutes les barres collectrices et les raccords de refroidis-

sement pour éviter de les toucher par inadvertance.

D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D 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 D’autres consignes de sécurité sont nécessaires dans les conditions

suivantes : risques électriques dans un environnement humide ou si
l’on porte des vêtements mouillés ; sur des structures métalliques telles
que sols, grilles ou échafaudages ; en position coincée comme assi­se, à genoux ou couchée ; ou s’il y a un risque élevé de contact
inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces
conditions, voir ANSI Z49.1 énuméré dans les normes de sécurité.
En outre, ne pas travailler seul !

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 nor­mes de sécurité).

D N’utiliser que des tuyaux de refroidissement non conducteurs ayant

une longueur minimale de 457 mm pour garantir l’isolation.

connexions de sortie sont sous tension lorsque

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

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.

D 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 raccor­dée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et revérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau­des.

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.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.
D 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.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.

D Avant de toucher des organes internes, couper l’onduleur,

débrancher l’alimentation et décharger les condensateurs
d’alimentation conformément aux instructions indiquées dans la
partie maintenance.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le chauffage à induction de certains matériaux,
adhésifs et flux génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour votre santé.

D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces

vapeurs.

OM-222 166 Page 4

D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs ap-

prouvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les adhésifs, les
flux, les métaux, les consommables, les revêtements, les nettoyants
et les dégraisseurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz provenant du
chauffage peuvent déplacer l’air, abaisser le niveau d’oxygène et
provoquer des lésions ou des accidents mortels. S’assurer que l’air
ambiant ne présente aucun danger.

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 Ne pas surchauffer des métaux munis d’un revêtement tels que

l’acier galvanisé, plaqué au plomb ou au cadmium, à moins que le
revêtement ne soit enlevé de la zone chauffée, que la zone soit bien
ventilée et, si nécessaire, en portant un respirateur. Les revêtements et
tous les métaux contenant ces éléments peuvent dégager des fumées
toxiques s’ils sont surchauffés. Voir les informations concernant la
température dans les spécifications de revêtement MSDS.

Risque D’INCENDIE OU D’EXPLO­SION.

D Ne pas surchauffer les composants .
D Attention aux risques d’incendie: tenir un ex-

tincteur à proximité.

D Stocker des produits inflammables hors de la zone de travail.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces

inflammables.

D Ne pas installer l’appareil à proximité de produits inflammables.
D 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 Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace

d’étincelles incandescentes ni de flammes.

D 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 Des pièces ou de l’équipement chaud peuvent

provoquer des blessures.

D Ne pas toucher ou manipuler la tête/l’enroulement à induction pen-

dant le fonctionnement.

D Ne pas toucher des parties chaudes à mains nues.
D 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.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance

LA CHUTE DE L’APPAREIL peut
blesser.

D Utiliser la poignée et demander à une personne

ayant la force physique nécessaire pour soule­ver l’appareil.

D Déplacer l’appareil à l’aide d’un chariot ou d’un

engin similaire.

D Pour les appareils sans poignée utiliser un équipement d’une ca-

pacité appropriée pour soulever l’appareil.

D 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.

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans les yeux.

D Porter des lunettes de sécurité à coques latéra-

les ou un écran facial.

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protec­tion.

D Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou­dage par points, de gougeage, du coupage plasma ou de chauf­fage par induction.

D Respecter le cycle opératoire nominal.

LES CHAMPS MAGNETIQUES peuvent
affecter des implants médicaux.

D Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

L’EMPLOI EXCESSIF peut SUR­CHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement
D Réduire le courant de sortie ou le facteur de mar-

che avant de recommencer le chauffage.

LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits im­primés.

D Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistati-

ques pour stocker, déplacer ou expédier des
cartes PC.

OM-222 166 Page 5

LE RAYONNEMENT HAUTE FRÉ­QUENCE (HF) risque de provoquer
des interférences.

D Le rayonnement haute fréquence (HF) peut

provoquer des interférences avec les équipe­ments de radio-navigation et de communication,
les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence.

2-4. Proposition californienne 65 Avertissements

LIRE LES INSTRUCTIONS.

D Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

D N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants).

Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can­cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site In­ternet : www.global.ihs.com).

OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten­dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

2-6. Information EMF

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org et www.sparky.org).

Code électrique du Canada, partie 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Mississauga, Ontario, Ca­nada L4W 5NS (téléphone : 800-463-6727 ou en Toronto416-747-4044,
site internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, de American National Standards Institute, 25

West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).

Considérations relatives au chauffage à induction et aux effets des champs
électriques et magnétiques basse fréquence.

Le texte suivant est extrait des conclusions générales Département du
Congrès U.S., Office of Technology Assessment, Effets biologiques des
champs magnétiques et électriques basse fréquence − Background Paper,
OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May

1989): “. . . on dispose maintenant d’importantes découvertes scientifiques
reposant sur des expériences effectuées dans le domaine cellulaire et
des études réalisées sur des animaux et des personnes qui démontrent
clairement que des champs magnétiques basse fréquence peuvent
avoir une interaction et produire des changements dans les systèmes
biologiques. Alors que la plus grande partie de cet ouvrage est d’une très
grande qualité, les résultats sont complexes. La compréhension scienti­fique courante ne nous permet pas encore d’interpréter la preuve fournie
dans un seul ouvrage cohérent. Il est encore plus frustrant de ne pas
pouvoir tirer des conclusions définitives en ce qui concerne les problèmes
de risque possible ou de proposer des recommandations scientifiques

OM-222 166 Page 6

claires pour des stratégies à suivre en vue de minimiser ou de prévenir
des risques potentiels.”

Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

4. Disposer le câble de sortie d’un côté à distance de l’opérateur

5. Ne pas enrouler ou draper le câble électrique autour du corps.

6. Placer la source de courant et le câble le plus loin possible de
l’opérateur.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précé­dentes.

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

Warning! Watch Out! There are
possible hazards as shown by the
symbols.

1 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

3-2. Warning Label Definitions (Continued)

12

4

3

5

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Electric shock from wiring can

kill.

3 Overuse can cause

overheating. Follow rated duty
cycle.

4 Disconnect input plug or

power before working on
machine.

5 Become trained and read the

instructions before working on
the machine.

6 Connect green or

green/yellow grounding
conductor to ground terminal.

7 Connect input conductors (L1,

L2 And L3) to line terminals.

6

123 4

7

194 466

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Electric shock from wiring can

kill.

3 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)
voltage (see Section 9-7).

OM-222 166 Page 8

227 085-A

3-3. Rating Label For CE Products

. For label location see Section 4-2.

3-4. WEEE Label (For Products Sold Within The EU)

226 534-B

Do not discard product (where ap­plicable) with general waste.

Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec­tion facility.

Contact your local recycling office
or your local distributor for further
information.

OM-222 166 Page 9

3-5. Symbols And Definitions

Frequency
Induct

Dimensions

. Some symbols are found only on CE products.

A

IP

U

I

1max

1

Amperes

Degree Of
Protection

Increase Line Connection

Primary Voltage

Rated Maximum

Supply Current

Remote Panel/Local High Temperature Voltage Input

Off On

V

Hz

U

P

1max

2

Volts Alternating Current

Hertz Circuit Protection Output

I

1

Load Voltage Read Instructions

Maximum Power

Consumption

Primary Current

Three Phase Percent

X

I

2

Duty Cycle

Rated Current

Three Phase Static

Frequency Con-

verter-Transform-

er-Frequency Con-

SECTION 4 − INSTALLATION

verter

4-1. Specifications

Output

Frequency

5 To 30

kHz

Storage Temperature Range −40_ F (−40_ C) to 122_ F (50_ C)
*While idling

Rated Output

Single

Output

35 kW At

100% Duty

Cycle

350 A

(RMS), 700

V (RMS)

Dual

Output

35 kW At

100% Duty

Cycle
700 A

(RMS),

700 V

(RMS)

Required

Reflective

ance

2.5 To 50
μh

400 V 460 V 575 V

60 A 50 A 40 A 39 37

Amperes Input at

Rated Load Output

50 or 60 Hz,

Three-Phase

kVA kW

Overall

Dimensions

Length: 36-3/4 in

(993 mm)

Width: 21-1/2 in

(546 mm)

Height: 29 in

(737 mm)

Weight

227 lb

(103 kg)

OM-222 166 Page 10

4-2. Selecting A Location

Movement

Location And Airflow

3

(305 mm)

4

1

12 in

OR

2

6

18 in

(460 mm)

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to

move unit.
If using lifting forks, extend forks

beyond opposite side of unit.
3 Rating Label (Non CE Models

Only)

Use rating label to determine input
power needs. Label located under
front access door.

4 Plate Label (CE Models Only)
Label located under power switch.
5 Rating Label (CE Models

Only)

Use rating label to determine input
power needs.

6 Line Disconnect Device
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.

4-3. Tipping

18 in

(460 mm)

12 in

5

(305 mm)

803 992-B

! Do not move or operate unit

where it could tip.

OM-222 166 Page 11

4-4. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

50 Hz
Three

Phase

Input Voltage 400 460 575
Input Amperes At Rated Output 60 50 40
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

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.

4

4

3

1

2

70 61 45
80 70 60

254
(77)

60 Hz Three Phase

6 8 8

214
(65)

8 8 10

334

(102)

Notes

OM-222 166 Page 12

4-5. Connecting 3-Phase Input Power For 460/575 Volt Models

! Installation must meet all National

GND/PE Earth Ground

! Disconnect and lockout/tagout in-

! Make input power connections to

3

! Always connect green or green/

8

. The circuitry in this unit automatically

7

10

See rating label on unit and check input
voltage available at site.

1 Input Power Conductors (Customer

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.

Welding Power Source Input Power
Connections

2 Strain Relief
Route conductors (cord) through strain re-

lief and tighten screws.
3 Machine Grounding Terminal
4 Green Or Green/Yellow Grounding

Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first.

5 Welding Power Source Line

6 Input Conductors L1 (U), L2 (V) And

Connect input conductors L1 (U), L2 (V)
and L3 (W) to welding power source line
terminals.

Close and secure access door on welding
power source.

Disconnect Device Input Power
Connections

7 Disconnect Device (switch shown in

8 Disconnect Device (Supply)

Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.

9 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V)

And L3 (W) to disconnect device line
terminals.

10 Over-Current Protection
Select type and size of over-current

protection using Section 4-4 (fused dis­connect switch shown).

Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

5

3/8 in

4

6

1

2

6

4

3

803 994-C

and Local Codes − have only quali­fied persons make this installation.

put power before connecting input
conductors from unit.

the welding power source first.

yellow conductor to supply
grounding terminal first, and never
to a line terminal.

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.

Supplied Cord)

Conductor

Terminals

L3 (W)

OFF position)

Grounding Terminal

OM-222 166 Page 13

4-6. Connecting 3-Phase Input Power For 400/460 Volt Models

Tools Needed:

3/8 in

3

8

9

4

= GND/PE Earth Ground

10

7

L1
L2L36

5

4

3

! Installation must meet all National and

Local Codes − have only qualified per­sons make this installation.

! Disconnect and lockout/tagout input

power before connecting input con­ductors from unit.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow

conductor to supply grounding termi­nal first, and never to a line terminal.

. 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.

See rating label on unit and check input volt­age available at site.

1 Input Power Conductors (Customer

Supplied Cord)

6

2

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.

Welding Power Source Input Power Con­nections

2 Strain Relief
Route conductors (cord) through strain relief

and tighten screws.
3 Machine Grounding Terminal
4 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding
conductor to welding power source grounding
terminal 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.

Close and secure access door on welding
power source.

1

Ref. 804 430-A

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.

9 Disconnect Device Line Terminals

Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.

10 Over-Current Protection

Select type and size of over-current protection
using Section 4-4 (fused disconnect switch
shown).

Close and secure door on line disconnect de­vice. Remove lockout/tagout device, and
place switch in the On position.

OM-222 166 Page 14

4-7. Power Source Output Connections

Single Air-Cooled

Output Connection

2

12

Single Liquid-Cooled

Output Connection

1

Dual Air-Cooled

Output Connection

12

4

Dual Liquid-Cooled
Output Connection

4

12

55

12

3

1 Output Connector 1
2 Output Connector 2
3 Protective Plug
4 Air-Cooled Extension Cable
5 Liquid-Cooled Extension Cable
The power source is capable of single or

dual output. When connected for single
power output, up to 35 kW is available at
the single output connection. When
connected for dual power, output power is
divided between the two output

12

4

3

connections.

Single Air-Cooled Output Connection

Connect air-cooled output extension cable
to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.

Single Liquid-Cooled Output Connection

Connect liquid-cooled output extension
cable to Output Connector 1 or Output
Connector 2. Connect Protective Plug to
remaining Output Connector.

5

Ref. 803 993-C / Ref. 804 217-A

Dual Air-Cooled Output Connection

Connect air-cooled output extension
cables to Output Connector 1 and Output
Connector 2.

Dual Liquid-Cooled Output Connection

Connect liquid-cooled output extension
cables to Output Connector 1 and Output
Connector 2.

. Extension cables must be the same

length: 25 ft (7.6 m) or 50 ft (15.2 m).

OM-222 166 Page 15

4-8. Remote 14 Receptacle RC14 Information and Connections

R

R

l

R

3

AJ

K

B

12

L

C

D

I

NH

M

G

F

E

4

2

1

1 Plug
2 Threaded Collar
3 Keyway
4 Remote 14 Receptacle RC14

(See Section 4-9)

To connect to receptacle, align key­way, insert plug and tighten
threaded collar.

803 993-C

4-9. Remote 14 Socket Information

Socket Socket Information

A
B

C
D
E
G

F, J Power Source Limit

H

I

L
M
N
K

OM-222 166 Page 16

emote Contactor

emote Output Contro

emote Metering

+24 volts dc.
Contact closure to A completes 24 volts dc contactor control circuit.

Command reference; +10 volts dc.
Control circuit common.
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.

Not used.
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.

4-10. Temperature Recorder Receptacle RC9 Information And Connections

1 Plug
2 Threaded Collar
3 Temperature Recorder

Receptacle RC9 (See Section
4-11)

3

12

2

1

To connect to receptacle, insert
plug and tighten threaded collar.

4-11. Temperature Recorder Socket Information

Socket No. Socket Information

1 Thermocouple No. 1 (TC1), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
2 Thermocouple No. 2 (TC2), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
3 Thermocouple No. 3 (TC3), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
4 Thermocouple No. 4 (TC4), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
5 Signal Common
6 Thermocouple No. 5 (TC5), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
7 Thermocouple No. 6 (TC6), 0-10 volt dc signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
8 Unused

9 Unused
10 Chassis Ground
11 Unused
12 Unused
13 Unused
14 Unused

803 993-C

OM-222 166 Page 17

4-12. Secondary Insulation Protection

1

2

Secondary insulation protection
circuitry automatically shuts down
the power source output if a
potentially hazardous condition
exists at the heating device
connected to the power source (e.g.
insulation has broken down on a
heating blanket causing the
conductor to come into contact with
the workpiece or a heating coil
touches the workpiece causing a
short in the output circuit).

The supplied ground lead(s) must
be connected between the
workpiece and power source to
provide proper secondary insula­tion protection from a short in the
output circuit.

For single output, only one
ground lead is required. For dual
output , use both ground leads.

1 Receptacles
2 Plug
To connect plug, align key with key-

way, insert end into receptacle, and
rotate plug until tight.

3 Handle
4 Magnet

. The secondary isolation magnet

must be in contact with bare
metal (free from rust, paint,
grease, etc.).

5 Workpiece
Use handle to place magnet on the

workpiece.

OM-222 166 Page 18

3

5

4

803 994-B / Ref. 801 826-C / Ref. 801 828-C

4-13. 115 Volt AC Duplex Receptacle And Supplementary Protector

1 115 VAC 2.5 A Single-Phase

2 Supplementary Protector CB1

The receptacle supplies nominal 115
volts ac auxiliary power for use with
the optional digital recorder. Maxi­mum output from receptacle is 2.5
amperes.

1

CB1 protects 115 volt receptacle
RC1 from overload. If CB1 opens,

12

RC1 does not work.

2

AC Receptacle RC1

(2.5 A)

803 993-C

4-14. Locating Thermocouples

Thermocouple location is one of the most critical steps in the Heat Treatment Operation.

Thermocouples shall be located as follows to provide a survey of heating uniformly and enable time and temperature control:

1. Locate thermocouples to ensure that the full area of the heat band is monitored.

S The code normally specifies the number of thermocouples to be used based on the pipe diameter.

S The control thermocouple is placed in the plane of the weld (center of the heat zone).

S The control thermocouple is placed at the top of the pipe in a standard pipe joint configuration. In other

applications, the thermocouple should be located in the hottest portion of the weldment to be stress relieved.

2. Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due to heat convection or
conduction, and have additional thermocouples applied.

3. Attach a spare thermocouple beside control thermocouples.

4. Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces.

5. Physically inspect all thermocouples for continuity and mark them by an identification number corresponding to the recorder channel.

6. Match the drawings of the workpiece indicating the numerous thermocouple locations, controlling thermocouple locations, etc. to weld identifi­cation information.

7. The system is equipped with 3-pin thermocouple connections at the front of the unit. Six thermocouples can be attached to the power source.

S The system is equipped with 3-pin connectors to accommodate shielded extension cables. The shielded

cables protect from electrical interference.

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

9. The following describes the thermocouple routing from work to power source.

S Type K thermocouple wire (two wire) is attached directly to the workpiece using a

Thermocouple Attachment Unit (see next section for information on attaching thermocouples).

S The other end is fitted with a 2-pin type K connector.

S The 2-pin connector plugs into the 3-pin composite extension cable. The extension cable has a six-channel

block of 3-pin female connectors. The pin size locates the position of the 2-pin connector on the extension.

S The extension cable contains six, 3-wire bundles of shielded cable.

S The 3-pin male extension cable plugs into the 3-pin female connector on the front of the power source.

1

3

4

For temperature control mode, the power
source must have (as a minimum) one
thermocouple connected to receptacle
TC1. If multiple thermocouples are desired,
either use individual thermocouple plugs or
the thermocouple extension cable.

To connect thermocouples to the power
source, proceed as follows:

2

. Do NOT weld thermocouples to work-

piece while thermocouple cable is con­nected to the power source.

Turn Off power source.
1 Power Source

2 Thermocouple Receptacles

3 Individual Thermocouple Extension

Cable

4 Multiple Thermocouple Extension

Cable

Align plug pin(s) with receptacle socket(s)
and push plug into receptacle.

OM-222 166 Page 20

804 320-A

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. Clean (file or grind) any loose scale or rust from the workpiece at the places where the wires will be attached.

3. Clean the location for the lead magnet to minimize resistance. Place the magnet as near to the thermocouple positions as possible.

4. Strip 1/4 inch of insulation from the thermocouple wires.

5. Set the output variable control of the TAU to about eighty percent (80%).

6. Grasp one of the stripped wires with the tip of the jaws of the application pliers.

. Don’t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit. This will cause

the thermocouple wire to fuse to the pliers, rather than the workpiece.

7. Press the end of the wire to the workpiece at ninety degrees to the surface, and maintain a firm pressure. Make sure the Thermocouple Attach­ment Unit is charged and wait for the ready light to glow.

8. Press discharge button, and the wire should weld to the workpiece. There will be a sharp crack and a slight arc flash.

9. Repeat the process with the other wire, placing it approximately 1/4 inch away from the first wire. Attach a spare thermocouple, and support
both thermocouples approximately 18 inches back from the connection with a band or fiber tape.

10. Carefully bend the wire over at right angles. This brings the thermocouple wires out along or parallel to the workpiece. It also tests the strength
of the weld. If the weld shows signs of breaking, remove the wire, restrip the end, and repeat the process.

Strap Or Tape

Thermocouple

Wires

804 322-A

OM-222 166 Page 21

4-16. Using Contact Thermocouples

The welded thermocouples discussed previously can be used for preheating or stress relieving. As an alternative, in preheating applications, a contact
temperature sensor* can be used. This eliminates the need to weld thermocouples and the sensor can be moved during the preheat process to check
temperatures at other locations on the joint.

. Removing the contact probe will display a short duration of heat drop on the temperature recorder, if used.

The contact temperature sensor can be plugged into the thermocouple extension cable or a Type K 25 ft. armored extension cable* can be used. One of
these extensions is required for each sensor.

In preheating applications, the thermocouple must be placed under the induction coil. Temperatures at the weld joint can be checked with temperature
sensitive crayons to verify the preheat temperature.

Welded thermocouples are normally used in stress relieving applications due to their accuracy.

*See product literature for item part number.

4-17. Placing Temperature Probe

1 Blanket
2 Temperature Probe
Place temperature probe between

blanket and metal material. The
probe must be in contact with the

1

2

material being heated. The tip of the
probe should be positioned in the
approximate center of the blanket
anywhere along the blanket length.

804 321-A

OM-222 166 Page 22

SECTION 5 − COMPONENTS AND CONTROLS

5-1. Controls

2

19

1811891076543

16

17

15

14
13
12

. When a control panel button is pushed

the yellow lamp lights to indicate ac­tivation.

1 Power Switch
Use switch to turn power source On and

Off.
2 TC1−4 Temperature Display
Provides temperature display of thermo-

couples 1 through 4.
3 Control Thermocouple LED’s
LED’s indicate which thermocouples (1−4)

are used to control the heating process.
4 Temperature Units LED’s
LED’s indicate units for temperature mea-

surements (°F or ° C).
5 Fault LED
LED lights to indicate a system fault condi-

tion.
6 Limit LED

LED lights to indicate a system limit condi­tion.

7 Heat On LED
LED lights to indicate the power source out-

put is energized.
8 Stop Button
Use button to stop a heating process.
9 Hold Button
Use button to hold a heating process.
10 Run Button
Use button to run a heating process.
11 Cursor Button
Use button to move selection cursor in the

4 x 40 LCD display (item 18).
12 Program Button
Use button to program the process control.
13 Run Status Button
Use button to display real time operating

status.

1

803 995-B

14 Parameter Button
Use button to display real time power

source operating parameters.
15 Cooler Button
Use button to turn cooler On and Off.
16 Increase Button
Use button to increase values in set-up

screen.
17 Decrease Button
Use button to decrease value in program

screen.
18 4 x 40 LCD Display
Displays programming, runs status, pa-

rameter, fault and limit conditions, and trou­bleshooting guide.

19 Thermocouple Input Receptacles
Use receptacles for type K thermocouple

inputs.

OM-222 166 Page 23

SECTION 6 − SETUP AND OPERATION

6-1. Safety Equipment

12

Wear the following during
operation:

1 Dry, Insulating Gloves
2 Safety Glasses With Side

Shields

DO NOT wear rings or watches
during operation.

sb3.1* 1/94

6-2. System Description

The ProHeat 35 Induction Heating Power Source is designed to function either as an air-cooled system or a liquid-cooled system. Depending on the
system type (either air-cooled or liquid-cooled), the power source is automatically configured to operate and provide an output appropriate for the type
of connected heating device.

A special identifier, embedded within the extension cable connector, provides the means for the power source to configure itself by recognizing the type
of extension cable(s) attached to its output connectors.

Designed to provide a single level of output (up to 35 kW), the ProHeat 35 power source has two panel mounted connectors that are connected in
parallel to the power source output. This design allows the system to operate with either a single output extension cable or two output extension cables.

If a single output extension cable is used, a protective plug (provided with the system) MUST be placed on the unused output connector or the system
will not operate. If two output extension cables are used, they both MUST be of the same type (either both air-cooled or both liquid-cooled) or the system
will not operate (in this case, the protective plug is not used). When two extension cables and heating devices are utilized on the system, the extension
cable lengths and heating devices MUST be identical (see Section 4-7).

The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal tempera­tures reach or exceed specific set limits (see Section 9).

6-3. Power Source/System Setup

kW

To view the System Setup screen, simultaneously press the Parameters

on the display:

A

and Program buttons and the following screen will appear

V

Hz

System Setup Screen

Degree Units: >_F SYSTEM SETUP

Tolerance...: ±25 Backlight: Yes

Input Type..: K TC Control Mode: Manual

Power Output: 35 KW System Lock: No

To change a setting:

S Press the Cursor button to move the cursor to the parameter to be changed

S Press Increase or Decrease button to select desired set-up feature.

OM-222 166 Page 24

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 button to select the desired temperature tolerance.

S The factory default is ±25 °F.

Backlight − press the Increase or Decrease button to turn LCD display backlight On or Off.

S The factory default is On.

Input Type − press the Increase or Decrease button to select the desired temperature input

device.

S The factory default and only selection is K TC.

Control Mode − press the Increase or Decrease button to select the desired method of system

control, either Temperature or Manual. For more details about methods of control, see Section
6-4.

S The factory default is temperature based control.

Power Output − press the Increase or Decrease button to adjust the maximum power source

output.

S The factory default is 35 kW.

System Lock − press the Increase or Decrease button to lock or unlock the operator interface to

prevent tampering with any programs. Yes indicates the system is locked, and No indicates the
system is unlocked.

S The factory default is No (unlocked).

. All parameters in System Setup are considered global, and any changes to the system set-up parameters will apply to all programs.

OM-222 166 Page 25

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

Programming allows the operator to setup a program for a particular heating process. The selections available are either Temperature control or Manual
control.

6-4-1. Temperature-Based Control

Temperature-based control operates the system and controls the heating process based on temperature feedback from thermocouple inputs. Ther­mocouples must be used for this mode of operation or the system will not operate. Within the temperature-based mode there are four different
processes available as follows: Preheat, Bakeout, PWHT (Post-Weld Heat Treat), and Custom Program.

Press the Program button to access the programming mode. Use the cursor button to move the cursor to the desired temperature-based process,
then press the Program button again to select the process.

6-4-1-1. Preheat

The preheat process is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time.

When this process is selected, the following screen will appear on the LCD display:

Preheat Screen

Mode.......: Preheat

Control TC.: 1

Temperature: 400

Soak Time..: 01:00:00

The default position of the cursor is next to Control TC. Press the Increase or Decrease button to select the number of control

thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.

Use the Cursor button to move the cursor to the desired selection (Temperature or Soak Time), and press the Increase or

Decrease button to change the value to the desired setting.

. The minimum and maximum temperature settings for preheat are 0 and 1000 F (−18 and 538 C). The minimum and maximum soak times are

0 and 1000 hours. When the system is utilizing air-cooled blankets, the maximum temperature setting is 400 F (204 C). If the program setting
is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is pressed:

OM-222 166 Page 26

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 _F, 204 _C)

6-4-1-2. Bake-Out

The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from bake-out if desired. When this

process is selected, the following screen appears on the display:

Bake-Out Screen

Mode......: Bake−Out

Control TC:>1

Soak Temp.: 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 1000 F(−18 and 538 C). The minimum and maximum soak times

are 0 and 1000 hours. The minimum and maximum cool rates are 10 and 9999 /hr. When the system is utilizing air-cooled blankets, the maximum
temperature setting is 400 F(204 C). If the program setting is above 400 F (204 C), the following screen will appear on the LCD display when
the Run button is pressed:

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 _F, 204 _C)

6-4-1-3. PWHT (Post-Weld Heat Treat)

The post-weld heat treat process allows the operator to program a post-weld heat treat where ramp temperature (on increase and decrease) and

ramp rates are the same. When this process is selected, the following screen appears on the display:

PWHT Screen

Mode......: PWHT

Control TC:>1,2

Ramp Temp.: 200 Ramp Rate: 600 _/Hr

Soak Temp.: 400 Soak Time: 01:00:00

OM-222 166 Page 27

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 Temp

Soak Time

Ramp Rate

Ramp Temp

Figure 6-1. Soak Parameters

. The minimum and maximum ramp temperature settings for PWHT are 0 and 1450 F (−18 and 788 C). The minimum and maximum ramp rates

are 10 and 9999 F/hr (6 and 5555 C/hr). The minimum and maximum soak temperatures are 0 and 1450 F (−18 and 788  C). The minimum
and maximum soak times are 0 and 100 hours. When the system is utilizing air-cooled blankets, the maximum temperature setting is 400 F (204
C). If the program setting is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is pressed.

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 _F, 204 _C)

6-4-1-4. Custom Program

In Custom Program, the operator can create a custom program with multiple steps or nonsymmetrical heat treat programs where the heating and

cooling rates and temperatures are different. When this process is selected, the following screen appears on the display:

. This is the screen for initial use of the system. Subsequent use of custom program will revert to the last program used.

OM-222 166 Page 28

Custom Program Screen

Mode.......: Custom Program

Segment....: 1

Type.......: End

Control TC.: 1

The default position of the cursor is next to Segment. Press the Increase or Decrease button to increase or decrease the

segment number, unless the segment type is End. In this case, the segment number will advance to segment 1.

Use the Cursor button to move the cursor to the desired selection (Type or Control TC), and press the Increase or Decrease

button to change the value to the desired setting. When the cursor is moved to the Type selection, pressing the Increase or

Decrease button changes the segment type to Step, Ramp, Soak, or End. The functions of each segment type are as follows:

S Step increases the temperature in the part at full-programmed power. A maximum temperature of 1450° F

(788° C) can be programmed.

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

or Decrease button.

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

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 button again automatically advances the program to the next segment

number.

Notes

OM-222 166 Page 30

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.

OM-222 166 Page 31

Typical 5-Segment Custom Program

Custom Program Screen

Mode.......: Custom Program

Segment....: 1

Type.......:>Step

Temperature: 600

Temperature increases to 600 degrees at full-programmed power.

Custom Program Screen

Mode.......: Custom Program

Segment....: 2

Type.......: Ramp

Temperature:>1250 Ramp Rate: 600 _/Hr

Controlled heating to 1250 degrees F at a ramp of 600 degrees per hour.

Custom Program Screen

Mode.......: Custom Program

Segment....: 3

Type.......: Soak

Soak Time..:>01:00:00

Soak at 1250 degrees F for a period of 1:00.

Custom Program Screen

Mode.......: Custom Program

Segment....: 4

Type.......:>Ramp

Temperature: 600 Ramp Rate: 600 _/Hr

Controlled cooling to 600 degrees F at a rate of 600 degrees per hour.

Custom Program Screen

Mode.......: Custom Program

Segment....: 5

Type.......: End

Control TC.: 1

End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.

6-4-2. Manual Control

Manual control allows programming of a specific power level for a specific period of time. When this process is selected, the following screen appears
on the display:

OM-222 166 Page 32

Manual Program Screen

Mode....: Manual Power..: 0.0 KW

Command.: 0.0 KW Current: 0 A

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 TC5: 77

Target Temp: −−−− TC6: 77

Countdown..: −−:−−:−−

Status.....: Stopped

Mode displays the programming mode (Preheat, Bake-Out, PWHT, or Custom Program). During active operation, Target Temp shows the target
temperature based on the specific program, Countdown shows the time remaining in a soak segment, and Status shows the program segment type
(step, soak, ramp, hold, or stopped). TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.

6-5-1-2. Custom Program

Run Status Screen

Mode.......: Custom Program TC5: 77

Target Temp: −−−− TC6: 77

Countdown..: −−:−−:−− Segment: 1

Status.....: Stopped

During active operation, Target Temp shows the target temperature based on the active segment, Countdown shows the time remaining in a soak
segment, and Status shows the program segment type (step, soak, ramp, hold, or stopped) of the active segment and the active segment number.
TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.

OM-222 166 Page 33

6-5-2. Manual Control

Run Status Screen

Mode.....: Manual TC5: 77

Power....: 0.0 KW TC6: 77

Countdown: −−:−−:−−

Status...: Stopped

During active operation, Power shows the actual power delivered from the power source, Countdown shows the time remaining in the heating cycle,
and Status indicates if the system is running or stopped. TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for
monitoring purposes only.

. No changes can be made to the run status screen, and the Cursor, Increase and Decrease buttons are not functional.

6-6. Parameters

During active operation, the Parameters screen allows the operator to monitor the power source output operating parameters. These parameters in­clude output power, output amperage, output voltage, and output frequency. In addition, temperatures of thermocouples TC5 and TC6 are also
displayed. The Parameters screen is for monitoring purposes only and has no selectable or changeable parameters.

Parameters Screen

Power....: 0.0 KW TC5: 77

Current..: 0 A TC6: 77

Voltage..: 0 V

Frequency: 4.5 KHz

6-7. Cooler

The Cooler button is used to turn the cooler On or Off on systems using liquid-cooled output cables. Systems using liquid-cooled output

cables will not deliver output unless the cooler is On. If the cooler is not started prior to initiating a heating cycle, the system will automatically start the

cooler when the Run button is pressed. Pressing the Stop button does not shut off the cooler. The cooler must be shut off separately

by pressing the Cooler button.

When power source output is energized, the cooler cannot be turned off. If the Cooler button is pressed while output is energized, the follow-

ing screen will appear on the display:

OM-222 166 Page 34

Cooler Message Screen

Cooler cannot be turned off

while output is on

. 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 The Stop button indicator LED illuminates to indicate no heating cycle is in process.

S The temperature displays indicate actual temperature from the TC’s (thermocouples). If no thermocouples

are connected, the displays indicate OPEN.

S Control LED’s illuminate to indicate the number of control TC’s in the last program.

S The appropriate degree units (°F or °C) light illuminates.

S The display defaults to the Run Status screen from the last program used and the Run Status

button indicator LED illuminates.

S If no fault or limit conditions are present, system status lights are not illuminated.

Once set up is complete for the desired program procedure (see Section 6-3), pressing the Run button will 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

OM-222 166 Page 35

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 Use the Cursor button to move the cursor to the parameter that will be changed.

S Press the Increase or Decrease button to make desired changes.

S Press the Run 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 num­ber can be changed; however, if the operation of a segment has already been completed in a program, the change to that segment will not affect the
program function.

S Press the Stop button to end the program.

OM-222 166 Page 36

6-9. System Operating Characteristics

Single Liquid Cooled

Dual Liquid Cooled

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

Air Cooled Single and Dual

down to limit current to 150 am­peres per output for continuous

operation.

See Note 1 700 V 25.7 − 30 kHz

350 A 700 V 5 − 20 kHz

See Note 2 700 V 20 − 30 kHz

350 A per output/700 A total 700 V 5 − 20 kHz

See Note 2 700 V 20 − 30 kHz

700 V 5 − 25.7 kHz

300

250

200

150

100

Max Amperage Per Output

50

0

400

350

300

5 25.7 30

Air Cooled Output

Frequency (KHz)

Liquid Cooled Output

. Note 1: In the frequency range

of 25.7 to 30 KHz, the maxi­mum output amperage de­creases linearly from 250 down
to 175 amperes per output. Re­gardless of frequency, after 15
minutes the maximum output is
reduced to 150 amperes per
output.

. Note 2: In the frequency range

of 20 to 30 KHz, the maximum
output decreases linearly from
350 down to 175 amperes per
output.

250

200

150

Max Amperage Per Output

100

50

0

52030

Frequency (KHz)

OM-222 166 Page 37

SECTION 7 − MAINTENANCE

7-1. Routine Maintenance

Every

3

Months

Every

6

Months

! Disconnect power

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

2

1

l Damaged or Unreadable
Labels

12

n Integrity Of Protective
Plug, Replace If Necessary

~ Output Connector Con­tacts

nlCracked Cables

~ Ground Sense Lead Re-

ceptacles

before maintaining.

2

1

. Maintain more often

during severe conditions.

Reference

Section 4-7,
4-12

~ Operator Interface Over­lay

Section 9-8

~ Inside Unit

OM-222 166 Page 38

SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING

Protect yourself and others from injury — read and follow these precautions.

8-1. Symbol Usage

OM-222166J - 2007−06, safety_ihtm 2007−04

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

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

NOTICE − Indicates statements not related to personal injury.

8-2. Servicing Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.

Only qualified persons should service, test, maintain, and re­pair this unit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

D Do not touch live electrical parts.
D Turn Off induction heating power source and

disconnect and lockout input power using line
disconnect switch, circuit breakers, or by removing plug from recep­tacle, or stop engine before servicing unless the procedure specifi­cally requires an energized unit.

D Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

D When testing a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

D Disconnect input power conductors from deenergized supply line

BEFORE moving an induction heating power source.

. Indicates special instructions.

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

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or face

shield during servicing.

D Be careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Do not touch or handle induction head/coil

during operation.

D Keep metal jewelry and other metal personal

items away from head/coil during operation.

D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

EXPLODING PARTS can cause injury.

D Failed parts can explode or cause other parts to

explode when power is applied to inverters.

D Always wear a face shield and long sleeves

when servicing inverters.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Troubleshooting Section be­fore touching any parts.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

D Do not place unit on, over, or near combustible

surfaces.

D Do not service unit near flammables.

SHOCK HAZARD from testing.

D Turn Off induction heating power source be-

fore making or changing meter lead connec­tions.

D Use at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

D Read instructions for test equipment.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of
unit.

OM-222 166 Page 39

MOVING PARTS can cause injury.

H.F. RADIATION can cause interference.

D Keep away from moving parts such as fans.
D Have only qualified persons remove doors,

panels, covers, or guards for maintenance as
necessary.

D Keep hands, hair, loose clothing, and tools away from moving

parts.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away from serv-

icing areas until consulting their doctor and the

device manufacturer.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.
D 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

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment install, test, and service
H.F. producing units.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

READ INSTRUCTIONS.

D Use Testing Booklet (Part No. 150 853) when

servicing this unit.

D Consult the Owner’s Manual for induction heat-

ing safety precautions.

D Use only genuine replacement parts from the

manufacturer.

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

8-4. EMF Information

Considerations About Induction Heating And The Effects Of Low Fre­quency Electric And Magnetic Fields

Induction heating current, as it flows through induction heating cables,
will cause electromagnetic fields. There has been and still is some
concern about such fields. However, after examining more than 500
studies spanning 17 years of research, a special blue ribbon committee
of the National Research Council concluded that: “The body of
evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human­health hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when using induction heating equipment.

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep induction heating power source and cables as far away
from operator as practical.

5. Connect work clamp to workpiece as close to the weld as
possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-222 166 Page 40

SECTION 9 − DIAGNOSTICS & TROUBLESHOOTING

The ProHeat 35 power source has on-board capabilities to aid in troubleshooting problems should any conditions occur during operation. This
troubleshooting capability consists of the Fault LED, Limit LED, and message screens that appear on the front panel LCD display.

9-1. Operator Interface Indicators

2

1

3

1 Fault LED

LED lights to indicate a system fault
condition.

2 Limit LED

LED lights to indicate a system limit
condition.

803 995-B

3 4 x 40 LCD Display
Displays programming, run status, param-

eters, fault and limit conditions, and
troubleshooting guide.

OM-222 166 Page 41

9-2. Limit Conditions

A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its optimum operating conditions or
parameters. Should a limit condition occur during operation, the yellow Limit LED will flash to indicate a problem. If the active screen on the LCD display
is Run Status or Parameters, a message describing the particular limit condition will appear on the display. If the active screen is Program, press the

Run Status button to display the limit condition.

In a limit condition, the power source will continue to deliver output power and protect itself from damage by reducing the output power. This situation
allows the operator time to determine the best action to correct the problem as described by the limit message on the LCD display.

If a limit condition occurs, there are two selectable options:

S Acknowledge the limit and continue operation.

S Terminate operation to correct the problem causing the limit.

Pressing the Decrease button will acknowledge the limit and continue operation with the existing set up. In the acknowledge state, the yellow

Limit LED will stop flashing and remain on continuously. The LCD display will revert to an active screen once the Program button, Run Status

kW

button, or Parameters

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

A

button is pressed.

V

Hz

condition, press the Run Status button and the LCD display will show a message describing the new and previous limit messages.

To obtain additional information regarding the limit condition and suggested solutions to resolve the limit, press the Increase button, and the

LCD display will indicate possible solutions based on the type of limit condition.

If the operator determines that the best course of action is to terminate operation and make suggested changes to the setup to eliminate the limit 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

L02: Themocouple #2 Open Check for open temperature sensor and repair

L03: Thermocouple #3 Open Check for open temperature sensor and repair

L04: Thermocouple #4 Open Check for open temperature sensor and repair

L05: Thermocouple #5 Open Check for open temperature sensor and repair

L06: Thermocouple #6 Open Check for open temperature sensor and repair

L07: Output Voltage Limit Tighten blanket against pipe surface
L08: Output Voltage Limit Increase number of turns

L09: Output Current Limit Tighten blanket against pipe surface
L10: Output Current Limit Increase number of turns

Change to back-up temperature sensor

Change to back-up temperature sensor

Change to back-up temperature sensor

Change to back-up temperature sensor

Change to back-up temperature sensor

Change to back-up temperature sensor

Increase coil space
Shorten extension cable
Increase insulation width

Decrease coil space
Tighten cable on insulation

OM-222 166 Page 42

Limit Condition Additional Information

L11: Coolant Overtemp Limit Check coolant flow and level

L12: Power Source Overtemp Limit Check for blocked vents

L13:Cable Connection Check for loose/open output connection

Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness

Clean wind tunnel heat sinks

Verify all output cables are same type
Verify receptacle plug connected

9-4. Fault Conditions

A fault condition occurs if the system encounters an isolation fault, encounters operating conditions outside operational limits, or if there is a serious

problem with the system. Should a fault condition occur, the output is immediately turned off, the red Fault LED flashes and the Stop button

LED flashes. If the active screen on the LCD display is Run Status or Parameters, a message describing the particular fault condition will appear on the

display. If the active screen is Program, press the Run Status 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 Additional Information

F51: Thermocouple #1 Internal Fault Service required
F52: Themocouple #2 Internal Fault Service required
F53: Thermocouple #3 Internal Fault Service required
F54: Thermocouple #4 Internal Fault Service required
F55: Thermocouple #5 Internal Fault Service required
F56: Thermocouple #6 Internal Fault Service required
F57: CJT Sensor Internal Fault Service required
F58: Output Voltage Fault Service required
F59: Output Current Fault Service required
F60: Temperature Sensor Fault Check control TC connections

F61: Coolant Flow Fault Check for coolant leak

F62: Isolation Fault Check for exposed conductor

F63:Line Voltage Fault Check line voltage
F64: Power Source Overtemp Fault Verify power source vents and

F65: Current Source Fault Service required
F66: Under Frequency Fault Check for loose or open connections

Check control TC extension cable

Clean for coolant blockage
Check coolant filter and level
Check coolant connections

Clean for moisture on cables

wind tunnel are unobstructed

in output cable
Decrease number of turns
Decrease coil space

OM-222 166 Page 43

Fault Condition Additional Information

F67: Over Frequency Fault Verify heating cable properly wrapped

F68: Cable Connection Fault Check for loose/open output connection

F69: Coolant Overtemp Fault Check coolant flow and level

F70: Internal Communication Fault Service required
F71: Internal Thermistor Fault Service required
F72: Coolant Thermistor Fault Service required
F73: Decoupled/Open Coil Service required
F74: Isolation Fault Self-Test Error Service required
F75: Internal Power Supply Fault Service required
F76: Current Source Control Fault Service required
F77: Power Source Internal Comm Fault Service required
F78:Output Current Sense Fault Check for loose/open output connection

Verify material being heated is magnetic

Verify all output cables are same type
Verify receptacle plug connected

Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness

9-6. System Diagnostic Screens

Additional system diagnostics are available and accessible through the operator interface. Detail operational parameters can be accessed by pressing

kW

and holding the Run Status button and pressing the Parameters

When this feature is initially activated, the following screen appears on the LCD display:

V

A

Hz

button.

System Diagnostic Screen

RemCmd: 1023 Off Cable1: LQD DIAG1

OutI1: 0 A Cable2: LQD

OutI2: 0 A ClntFR: 0.75 GPM

IsrcFb: 0 A ClrSts: Flowing

RemCmd − This is the value of the remote command and the status of the remote contactor.

. Remote controls can be used to enable/disable output. They do not affect output power level.

Out I1 − This is the value of the output current on output 1.

Out I2 − This is the value of the output current on output 2.

Isrc FB − This is the value of the amperage in the current source inverter.

Cable 1 − This is the cable type hooked up to output number one. Possible labels:

S AIR − for an air-cooled cable

S LQD − for a liquid-cooled cable

S PLUG − for a protective plug

S OPEN − no cable or plug in place

Cable 2 − This is the cable type hooked up to output number two. Possible labels:

S AIR − for an air-cooled cable

S LQD − for a liquid-cooled cable

S PLUG − for a protective plug

OM-222 166 Page 44

S OPEN − no cable or plug in place

ClntFR − This is the coolant flow rate (in GPM) from the cooler on a liquid-cooled system.

ClrSts − This is the status of the cooler. Possible labels:

S Off

S Flowing

The second diagnostic screen is available by again pressing and holding the Run Status button and pressing the Parameters

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 OFF

S ON

kW

A

V

Hz

. RmtFlw feature is unsupported on the current platform.

OM-222 166 Page 45

9-7. Removing Wrapper and Measuring Input Capacitor Voltage

Tools Needed:

5/16, 3/8 in

1

! 900 Volts dc can be present

on the capacitor bus and
significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage on inverter assembly
as shown to be sure the input
capacitors have discharged
before working on unit.

! Turn Off welding power

source, and disconnect
input power.

! Significant DC voltage can

remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.

Remove right side panel and dis­connect fan motor FM3.

1 Current Source Interconnect

Board PC4
2 Voltmeter
Measure the dc voltage across the

+ bus terminal and − bus terminal on
PC4 as shown until voltage drops to
near 0 (zero) volts.

. If the capacitor voltage does

not drop to near zero after

several minutes, use a bleeder

resistor of between 200 and

500 ohms, at least 10 watts,

and #16 AWG 600 volts ac in-

sulation rated wire to discharge

the capacitor(s).

3 Typical Bleeder Resistor
An example of a typical bleeder

resistor is shown on this page.
Proceed with job inside unit. Re-

connect FM3 and reinstall right side
panel when finished.

+ lead to right bus terminal,

− lead to left bus terminal

OM-222 166 Page 46

3

Typical Bleeder Resistor

200 to 500 ohm, 10 watt

wire wound resistor

2

#16 AWG 600 Volts AC

Insulation Rating

804 519-B

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.

Notes

804 625-B

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

SECTION 10 − ELECTRICAL DIAGRAM

OM-222 166 Page 48

Figure 10-1. Circuit Diagram

218 057-G

OM-222 166 Page 49

SECTION 11 − PARTS LIST

See Figure

11-2

5

11

3

4

See Figure

11-3

. Hardware is common and

not available unless listed.

12

13

14

15

10

9

1

7

6

8

11

2

Figure 11-1. Wrappers

Item

No.

Dia.

Mkgs.

Part

No.

Description

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

804 218-D

Quantity

+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

. Hardware is common and

not available unless listed.

3

2

1

8

11

12

5

4

13

6

7

10

9

804 219-A

Figure 11-2. Front Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-2. Front Panel

1 217 323 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

. Hardware is common and

not available unless listed.

7

6

12

13

10

9

2

4

5

14

1

3

Item

No.

11

Dia.

Mkgs.

Part

No.

Figure 11-3. Rear Panel

Description

Figure 11-3. Rear Panel

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

804 220-A

Quantity

+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

. Hardware is common and

not available unless listed.

14

1

4

10

14

12

3

6

5

13

7

3

6

9

16

15

8

2

804 221-D

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Figure 11-4. Base w/Components

Description

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

. Hardware is common and

not available unless listed.

11

See

Figure 11-6

9

10

13

7

12

8

14

15

4

2

Figure 11-5. Top Windtunnel

3

1

5

6

804 222-A

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

. 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

. Hardware is common and

not available unless listed.

20

1

6

2

5

4

8

19

7

18

16

17

14

9

11

10

3

12

15

13

Figure 11-7. Right Windtunnel

Item

No.

Dia.

Mkgs.

Part

No.

Description

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

804 224-E

Quantity

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

. Hardware is common and

not available unless listed.

22

1

6

2

4

7

8

21

17

16

19

5

14

9

11

10

3

12

15

13

20

15

Figure 11-8. Right Windtunnel (400 V Model Only)

Item

No.

Dia.

Mkgs.

Part

No.

Description

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

804 431-E

Quantity

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

. Hardware is common and

not available unless listed.

12

1

10

14

8

3

5

9

15

6

13

7

11

2

4

804 225-A

Figure 11-9. Left Windtunnel

Item

No.

Dia.

Mkgs.

Part

No.

Description

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-222 166 Page 60

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

. Hardware is common and

not available unless listed.

4

3

2

1

6

7

8

1

9

5

3

4

804 300-A

Figure 11-10. Hermaphroditic Blank Plug Assy

Item

No.

Dia.

Mkgs.

Part

No.

Description

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-222 166 Page 62

Notes

SOCKET/WRENCH SELECTION TABLE

(U.S. STANDARD)

Specifications Socket or Wrench Size Specifications Socket or Wrench Size

Bolt

Diameter

1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm

5/16 in .3125 in 1/2 in 9/16 in 8 mm .3150 in 14 mm 14 mm

3/8 in .375 in 9/16 in 5/8 in 10 mm .3937 in 17 mm 17 mm

7/16 in .4375 in 5/8 in 3/4 in 12 mm .4724 in 19 mm 19 mm

1/2 in .500 in 3/4 in 13/16 in 14 mm .5512 in 22 mm 22 mm

9/16 in .5625 in 7/8 in 7/8 in 16 mm .6299 in 24 mm 24 mm

5/8 in .625 in 15/16 in 1 in 18 mm .7087 in 27 mm 27 mm
3/4 in .750 in 1-1/8 in 1-1/8 in 22 mm .8661 in 32 mm 32 mm
7/8 in .875 in 1-5/16 in 1-5/16 in 24 mm .9449 in 36 mm 36 mm

1 in 1.000 in 1-1/2 in 1-1/2 in

Decimal

Equivalent

Bolt Nut

SOCKET/WRENCH SELECTION TABLE

(METRIC)

Bolt

Diameter

U.S.

Decimal

Equivalent

Bolt Nut

OM-222 166 Page 63

Notes

OM-222 166 Page 64

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

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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

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.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 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.)

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
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

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.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

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