Download Miller Electric Intellifire 250 Specifications

OM-184 227C
December 1999
Miller
Processes
Induction
:~:~
Heating
The Power ofBlue.
Description
Induction
Heating
Power Source
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Intellifire 250
U
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HP
Visit
our
website at
www.MillerWeldscom
OWNERS
MANUAL
From Miller to You
congratulations on choosing Miller. Now
get the job done and get it done right. We know
Thank you and
you
can
you dont
Thats
have time to do it any other way.
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 couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
why
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Today,
the
~llll~Wfl~
Working
This Owners
Miller
help
designed help you get the most out of your
Please take time to read the Safety precautions. They will
Manual is
products.
you protect
to
yourself against potential
hazards
IJIJI
~
I
the worksite. Weve
operation quick
made installation and
~I
on
as
hard
as
you do
every power source from
Miller is backed by the most
hassle-free warranty in the
-
business.
and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
liii
REGISTERED
the unit needs repair, theres a
Troubleshooting section that will help you
QUALITY SYSTEM
some reason
V
Miller
is
first
the
welding
manufacturer
equipment
in
out what the
will then
the U.S.A. to be
the ISO 9001
figure
registered to
Quality System
Standard.
parts list
decide which exact part
problem
help
is. The
you to
you may need to fix the problem. Warranty and
service information for your particular model
are
also
provided.
Miller offers
a
Manual which
more
Technical
provides
detailed se,vice and
parts information for your
unit. To obtain
a
Technical
Manual, contact your locai
distributor. Your distributor
can
also
Welding
such
as
GMAW,
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
related
other
equipment.
quality Miller
contact your local Miller distributor
to receive the latest full line
individual
catalog
or
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
catalog
2
supply you with
Process Manuals
SMAW. GTAW.
and GMAW-P.
TABLE OF CONTENTS
SECTION 1
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
1-4.
Symbol Usage
Induction Heating Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-1.
1-2.
1-3.
SECTION 1
-
1
and Maintenance
2
3
route, de fonctionnement et dentretien
4
de mise
1-2.
Informations concernant les
PRINCIPALES NORMES DE
en
champs electro-magnØtiques (Information EMF)
SECURITE
5
5
6
INSTALLATION
6
2-3.
Specifications
Connecting Head/Coil to Power Source
Remote 14 Receptacle RC14 Information
2-4.
Remote 14 Socket Information
7
2-5.
Connecting Input
8
2-6.
Electrical Service Guide
2-1.
2-2.
6
and Connections
Power
SECTION 3- OPERATION
3-1.
Controls
SECTION 4- MAINTENANCE & TROUBLESHOOTING
7
9
.9
9
10
4-1.
Routine Maintenance
10
4-2.
Overheating
10
4-3.
Automatic Shutdown Protection
10
4-4.
Safety Interlock Switch
Measuring Tuning Capacitor Voltage
Optional Ground Fault Protection
Optional Ground Fault Protection
Measuring Input Capacitor Voltage
Diagnostic LEDs
Troubleshooting
Tuning Chart
10
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
SECTION 5- ELECTRICAL DIAGRAM
SECTION 6
-
WAR RANTY
OM-184 227C
2
2
Dangers supplØmentaires
-
1
MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION
1-1.
SECTION 2
1
PARTS LIST
11
11
12
13
14
15
15
17
19
S
S
SECTION 1
SAFETY PRECAUTIONS
USING
-
READ BEFORE
-
Symbol Usage
11.
salety_ihom 5/98
Out! There are possible
hazards with this procedure! The possible hazards are
shown ri the adjoining symbols.
4A
A
Marks
special safety message.
a
~ Means Note~
not
related.
safety
The
the
are used throughout this manual
identify possible hazards. When you
shown below
symbols
to call attention to and
see
of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
This group
Induction Heating Hazards
:i.~..
A
Watch
Warning!
Means
symbol,
watch out, and followthe related instructions
safety information given below is
to avoid the hazard. The
summary of the more complete safety information
found in the Safety Standards listed in Section 1.4. Read and
follow all Safety Standards.
only
a
should
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any
Only qualified persons
repair this unit.
A
During operation, keep everybody, especially children, away.
parts.
INDUCTION HEATING
install, operate, maintain, and
A
internal
can cause
parts and equipment
Hot
Do not touch
can
burns.
injure.
handle induction head/coil
or
during operation.
ELECTRIC SHOCK can kill.
live electrical parts can cause fatal
shocks or severe burns. The power circuit and
output bus bars or connections are electrically live
whenever the output is on. The input power circuit
and machine internal circuits are also live when power is on.
Incorrectly installed or improperly grounded equipment is a hazard.
cooling period
Do not overheat
dry, hole-free insulating gloves
and
fittings
to
from
FIRE OR EXPLOSION hazard.
parts.
Enclose any connecting bus bars and coolant
unintentional contact.
Wear
before
handling parts or equipment.
Keep metal jewelry and other metal personal items away
head/coil during operation.
Touching
Do not touch live electrical
parts bare-handed.
Do not touch hot
Allow
prevent
Watch for fire;
Keep
body protection.
yourself from work and ground using dry insulating mats
big enough to prevent any physical contact with the work
or ground.
Disconnect input power before installing or servicing this equip
ment. Lockout/tagout input power according to OSHA 29 CFR
191 0.147 (see Safety Standards).
Use only nonconductive coolant hoses with a minimum length of
18 inches (457 mm) to provide isolation.
parts
and adhesive.
keep extinguisher nearby.
flammables away from work
Do not locate unit on, over,
area.
combustible surtaces.
or near
Insulate
Do not install unit
near
flammables.
or covers
Properly
install
ground
and
this
equipment according
to
operate unit
-
making input connections,
conductor first
proper grounding
attach
double-check connections.
-
Keep
If
-
can
be hazardous
your head out of the fumes. Do not breathe the fumes.
inside,
ventilate the
area
and/or
use
exhaust to
remove
fumes
and gases.
approved air-supplied respirator.
If ventilation is poor,
use an
Material
Safety
Read
the
manufacturers
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
explosive atmosphere.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breath
ing these fumes and gases can be hazardous to
your health.
its
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
in
FUMES AND GASES
Manual and national, state, and local codes.
Owners
When
Do not
instruction
Data
for
Sheets
(MSDS5)
adhesives,
and
fluxes,
the
metals,
consumables, coatings, cleaners, and degreasers.
-
Turn off all
equipment
Do not
worn,
use
Do not
drape
when not in
use.
damaged, undersized,
cables
over
your
or
poorly spliced
cables.
body.
Do not touch power circuit if you are in contact with the work,
ground, or another power circuit from a different machine.
Use
I
well-maintained
equipment. Repair replace damaged
according to manual.
only
parts at once.
Maintain unit
Wear
a
harness if
Keep
all
safety
panels
and
or
working
covers
above floor level.
securely
in
place.
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.
Work in
Do not heat in locations
near
erations. The heat
react with vapors to form
can
degreasing, cleaning, or spraying op
highly toxic and
irritating gases.
Do not overheat coated metals, such as galvanized, lead, or
plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and if necessary, while
cadmium
an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if overheated.
See coating MSDS for temperature information.
wearing
OM-184 227
Page
1
1-3
Additional
Symbols
FALLING UNIT
for Installation,
can cause
Operation,
and Maintenance
injury
Use handle and have person of
unit.
OVERUSE
adequate
Allow
physical strength lift
Move unit with hand cart
For units without
a
adequate capacity
When
or
handle,
similar device.
equipment
use
of
cooling period.
Reduce
output
starting
to heat
Follow rated
using lift forks to move unit, be sure forks are long enough
beyond opposite side of unit.
boards
Use proper
MOVING
can cause
Keep away from moving parts
Keep
side
store, move,
panels, covers,
securely in place.
as
and
guards
only qualified person familiar
perform this installation.
wearers
induction
user
responsiblefor having
is
correct any interference
tion.
keep away.
If notified
by
a
qualified
the FCC about interference,
equipment
electrician
prompt
from the installa
stop using the equip
ment at once.
heating operations.
Have the installation
Keep high-frequency
checked and maintained.
regularly
source
doors and
panels tightly
shut.
Principal Safety Standards
1910, from Superinten
Printing Office, Washington,
Canadian Electrical Code Part 1, CSA Standard C22. 1, from Cana
Standards Sales,
178 Rexdale
dian Standards Association,
Boulevard,Rexdale, Ontario, Canada M9W 1 R3.
Code, NFPA Standard 70, from National Fire Pro
Batterymarch Park, Quincy, MA 02269.
Safe Practices ForOccupationAnd Educational EyeAnd Face Protec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Safety and Health Standards, OSHA
29 CFR
dent of Documents, U.S. Government
D.C. 20402.
National Electrical
tection Association,
1-5.
boxes to
interference.
with electronic
problem resulting
ly
Wearers should consult their doctor before
1-4.
BEFORE
parts.
cancause
Have
The
near
strap
boards
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
fans.
MAGNETIC FIELDS can affect pacemakers~
going
or
static-proof bags and
or ship PC boards.
H.F. RADIATION
I:
injury.
such
all doors,
Pacemaker
before
face shield.
PARTS
closed and
with
wrist
grounded
on
handling
injure eyes.
approved safety glasses
or wear
duty cycle
(ESD) can damage PC
STATIC
Put
FLYING METALOR ADHESIVE can
shields
reduce
or
again.
duty cycle.
to lift unit.
to extend
Wear
OVERHEATING
can cause
EMF Information
questions
strategies
of
The
To reduce
magnetic
the U.S.
dures:
Considerations About Induction
quency Electric And
Magnetic
Heating
And The Effects Of Low Fre
Fields
following is a quotation from the General Conclusions Section of
Congress, Office of Technology Assessment, Biological Ef
fects of Power Frequency Electric & Magnetic Fields
Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Of
there is now a very large volume of scientific
fice, May 1989): .
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 in
terpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
possible
risk
or
to offer clear science-based advice on
to minimize or avoid
potential
fields in the
risks.
workplace,
use
the
following
proce
-
.
.
1.
Arrange output
2.
Do not coil
3.
Keep power
practical.
or
cable to
one
drape output
source
side and away from the
cable around the
and cable
as
operator.
body.
far away from the
operator
as
About Pacemakers:
The
above
wearers.
procedures
are
also
Consult your doctor for
recommended
complete
for
pacemaker
information.
S
OM-184 227
Page
2
SECTION 1
MESURES DE SECURITE POUR LE
CHAUFFAGE PAR INDUCTION
-
saletyihom_fre
LA
AVERTISSEMENT
5/98
peut Œtre dangereux.
LE CHAUFFAGE PAR INDUCTION
PRENDRE LES MESURES NECESSAIRES POUR EVITER. LES RISQUES DE BLESSURES GRAVES, VOIRE
ST!MULATEUR CARD!AQUE DOIVENT
MORTELLES. TENIR LES ENFANTS A DISTANCE. LES POP.TEURS DUN
PREALABLEMENT CONSULTER LEUR MEDECIN.
operations de chauffage, comme dans Ia plupart des activitØs, IopØrateur sexpose a certains dangers.
chauffage nest pas dangereux a condition de prendre certaines mesures. Les consignes de sØcuritØ indiquØes
ci-aprŁs ne sont quun rØsumØ des informations plus dØtaiflØes se trouvant dans les normes de sØcuritØ ØnumØrØes
Pendant les
Le
a Ia page suivante. Lire et respecter toutes les
normes
de sØcuritØ.
LES OPERATIONS DINSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT
ETRE CON FlEES QUA DU PERSONNEL QUALIFIE.
Danger de
mort PAR ELECTROCUTION.
de composants
contact
Ølectriques peut
provoquer des accidents mortels ou des brlures
graves. Le circuit de puissance et les connexions de
sortie sont sous tension lorsquon active Ia sortie. Le
circuit dalimentation et les circuits internes de Ia
machine sont egalement sous tension lorsque
est sur marche. Des Øquipements
lalimentation
installØs ou relies a Ia borne de terre de maniŁre
incorrecte sont dangereux.
7.
Installer et mettre cet Øquipement correctement a Ia terre
conformŁment au manuel utilisateur et aux codes riationaux,
gouvernementaux et locaux.
8.
Verifier souvent Ia terre de lalimentation contrler et sassurer
est
que le conducteur de terre du cØble dalimentation
correctement reliØ a a borne de terre dans le boltier de
dØconnexion ou que le connecteur est branchØ a une sortie de
boitier correctement mise a Ia terre.
9.
le
brancher dabord
En rØalisant des connexions dentrØe
contrler
deux fois les
conducteur de terre appropriØ
connexions.
Le
Ne pas toucher des
composants Ølectriques
sous
tension.
-
-
10.
Verifier souvent le bon Øtat du cable dalimentation ou Iisolation
des fils remplacer le cable immØdiatement siI est endommagØ
des fils dØnudŁs peuvent provoquer des accidents mortels.
-
2.
3.
Envelopper les connexions et raccords de refroidissement pour
Øviter tout contact accidentel.
ArrŒter tous
Ne pas utiliser des cables
dimensionnŁs ou mal ØpissŁs.
et du sol avec des tapis ou des
suffisamment grands pour prØvenir tout
Ia piŁce ou Ia terre.
13.
Ne pas porter les cables autour de votre corps.
Ne pas toucher le circuit Ølectrique si vous Œtes en contact avec
Ia piŁce, Ia terre ou le circuit electrique dune autre machine.
DØconnecter lalimentation avant dinstaller Iappareil ou den
Verrouiller
effectuer Ier,tretien.
ou
Øtiqueter Ia sortie
dalimentation
selon Ia norme OSHA 29 CFR 1910.147
15.
gants disolation
lsolez-vous de Ia
secs, sans trous, et une
protection
piŁce
couvertures disolation
contact
5.
physique
(se reporter
6.
sont pas utilisØs.
11.
12.
Porter des
corporelle.
4.
-
aux
avec
Principales
normes
de
sØcuritØ).
Utiliser seulement des tuyaux non conducteurs avec
Iongueur minimale de 460 mm pour assurer Iisolement.
14.
Øquipements Iorsquils
Utiliser seulement des
cu
Łquipements
remplacer immØdiatement
des
Effectuer des travaux dentretien
ne
uses,
endommagŁs,
bien entretenus.
sous
RØparer
composants endommagØs.
sur
Iappareil
Selon le manuel.
16.
Porter un harnais de
au-dessus du sd.
sŁcuritØ pour effectuer des travaux
17.
Maintenir solidement
place tous
une
LE CHAUFFAGE PAR INDUCTION peut
provoquer des blessures ou des
PIECES
brlures
de
contact
au
CHAUDES OU DE LEQUIPEMENT.
es
1.
en
es
panneaux et couvercles.
Ne pas toucher ou manipuler latŁte/lenroulement
le fonctionnement.
a induction
pendant
2.
3.
Tenir es bijoux et autres objets personnels en metal ŁloignØs
dela tete/del enroulement pendant le fonctionnement.
Laisser refroidir les composants ou equipements avant de es
manipuler.
LE CHAUFFAGE PAR INDUCTION
un incendie.
peut
pas surchauffer
adhØsifs.
1.
Ne
2.
Attention aux risques
extincteur a proximitØ.
3.
Stocker des produits inflammables hors de Ia
zone
es
ni
es
tenir
~n
composants
dincendie:
place de Iappareil sur, au-dessus ou a
de surfaces inflammables peut Œtre source
dINCENDIES OU d EXPLOSION.
La
mise
en
proximitØ
provoquer
1.
Ne pas placer Iappareil
surfaces infilammables.
2.
Ne pas installer
3.
Ne pas faire fonctionner
sur,
au-dessus
ou
a
proximitØ
de
Iappareil a proximitØ de produits inflammables
lappareil en atmosphere explosive.
de travail.
OM-184 227
Page
3
DES FUMEES ET DES GAZ peuvent
Œtre dangereux pour votre sante.
Le chauffage a induction gØnŁre des fumØes et des
gaz. Leur inhalation peut Œtre
sante.
5.
en
dangereuse pour votre
6.
1.
Eloigner
2.
A
Ia tŒte des fumØes. Ne pas
linterieur,
IØvacuation
3.
4.
respirer
ventiler a zone et/ou utiliser
des fumØes et des gaz.
Si Ia ventilation
alimentation dair
insuffisante,
est
les fumØes.
un
respirateur a
homologuØ.
specifications de sØcuritØ
7.
Dangers supplØmentaires
de mise
es
es
en
DØplacer lappareil
engin similaire.
charriot
ou
1. PrØvoir une
de ref roidissement
le facteur de marche nominal.
Respecter
~,
LELECTRICITE
STATIQUE peut endomma
ger les corn posants des tableaux Ølectriques.
1. Etablir Ia connexion
avec
Ia barrette de terre avant
manipuler des cartes cu des piŁces.
Utiliser des pochettes et des boites antistatiques
de
levage pour dØplacer
que les fourches sont suffisam
pour dØpasser du ctØ oppose de
4. En utilisant des fourches de
sassurer
longues
Iappareil.
pØriode
2. RØduire le courant de sortie ou le facteur de marche
avant de recommencer le chauffage.
lappareil.
ment
revŒtement tels que lacier
cadmium, a moms que le
au
dun
3. Pour les appareils sans poignØe utiliser un Øquipe
ment dune capacitØ appropriØe pour soulever
IunitØ,
ou
UNE UTILISATION INTENSIVE peut provo
un SURCHAUFFEMENT DU MATERIEL.
3.
dun
p10mb
quer
poignØe et demander a une personne
force physique nØcessaire pour soulever
a aide
au
route, de fonctionnement et dentretien
Iappareil.
2.
et irritants.
revŒtement ne soit enlevØ de Ia zone chauffØe, que Ia zone soit
bien ventilØe et, si nØcessaire, en portent un respirateur. Les
revŒtements et tous les mØtaux contenant ces ØlØments peuvent
degager des fumØes toxiques sils sont chauffØs.
es
1. Utiliser Ia
Ia
toxiques
Ne pas chauffer des mØtaux munis dun
LA CHUTE DE MATERIEL peut provoquer
des blessures personnelles graves et en
dommager les Øquipements.
ayant
un
respirateur. Demander toujours a
galvanisØ, plaque
dØgraisseurs.
1-1.
Un
Ne pas chauffer dans des endroits se trouvant a proximitØ
de dØgraissage, de nettoyage ou de pulvØrisation.
La chaleur peut rØagir en presence de vapeurs et former des gaz
hautement
utiliser
des matØriaux (MSDSs) et
es
instructions du fabricant concernant les adhØsifs, les mØtaux,
consommables, les revŒtements, les nettoyants et
Lire
portant
dopØrations
extracteur pour
Un
espace fermØ seulement sliest bien ventilØ ou
un surveillant
dment formØ de se tenir a proximitØ. Des fumØes et des gaz
provenant du chauffage peuvent dØplacer lair, abaisser le niveau
doxygŁne, et provoquer des lesions ou des accidents mortels.
Sassurer que air ambiant ne prØsente aucun danger.
Travailler dans
LA PROJECTION DE PIECES DE METAL ou
DE COLLE peut provoquer des blessures
aux yeux.
1. Porter des lunettes de
protection
avec
des
protec
tions latØrales.
DES
ORGANES
MOBILES
provoquer des blessures.
peuvent
1. Sabstenir de toucher des organes mobiles tels que
des ventilateurs.
2. Maintenir fermØs et fixement
neaux, recouvrements et
en place les portes, pan
dispositifs de protection.
2.
pour stocker,
dØplacer
Cu
expØdier
des cartes PC.
II subsiste DU COURANT CONTINU IMPOR
TANT
Ia mise hors tension de Ialimen
tation electrique.
a,prŁs
1. Avant de toucher des organes internes, arrŒter Ia
source electrique, dØbrancher lalimentation, et dØ
charger les condensateurs dalimentation confor
mØment aux instructions indiquØes dans Ia partie
maintenance.
FREQUENCE
avec les
Øquipements de radio-navigation et de com
munication, les services de sØcuritØ et les
ordinateurs.
LE
RAYONNEMENT
HAUTE
peut provoquer des interferences
Demander seulement a des personnes qualifiØes
avec des equipements Øiectroniques
de faire fonctionner Iinstallation.
familiarisØes
Lutilisateur
par
un
est tenu de faire
Ølectricien
qualifiØ
corriger rapidement
les interferences rØsul
tant de installation.
DES CHAMPS MAGNETIQUES CREES PAR
DES COURANTS ELEVES peuvent affecter
le fonctionnement du stimulateur cardiaque.
Si le FCC
diatement
Effectuer
1. Porteurs de stimulateur
2. Les
cardiaque,
restez a distance.
porteurs dun stimulateur cardiaque doivent
dabord consuiter leur mØdecin avant de sap
procher des operations de chauffage a induction.
OM-184 227
Page
4
signale des interferences, arrŒter immØ
lappareil.
rØguliŁrement
le contrle et Ientretien de
Iinstallation.
Maintenir
soigneusement fermŁs
panneaux des
sources
de haute
les
portes
frequence.
et les
.
1-2.
champs electro-magnØtiques (Information EMF
Informations concernant les
au chauffage a induction et aux effets des
magnØtiques basse frequence.
Le texte suivant est extrait des conclusions genØrales DØpartement
du CongrŁs U.S., Office of Technology Assessment, Effets
biologiques des champs magnØtiques et Ølectriques basse
frequence Background Paper, OTA-BP-E-53 (Washington, DC:
on dispose
U.S. Government Printing Office, May 1989): .
maintenant dimportantes dØcouvertes scientifiques reposant sur
des experiences effectuØes dans !e domaine cellulaire et des
Considerations relatives
pour des
champs Ølectriques
risques potentiels.
et
Pour rØduire
les
appliquer
Washington,
D.C. 20402.
Code Ø!ectrique national, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
sur
le
ou
de
prØvenir des
poste
de
travail,
suivantes:
le cable de sortie dun
ctØ
a distance de
ou
draper
!e cb!e
autour du
e!ectrique
corps.
Placer Ia
6.
de
En
ce
source
de courant et le cable le
plus
loin
possible
IopØrateur.
qui
concerne
les stimulateurs
cardiaques
Les procedures ci-dessus concernent egalement les porteurs de
Consulter votre mØdecin
stimulateur cardiaque.
pour un
complement dinformation.
PRINCIPALES NORMES DE
Normes de sØcuritØ et de sante, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
de minimiser
champs magnØtiques
Ne pas enrouler
5.
sur
ouvrage est dune trŁs grande qualitØ, les rØsultats sont complexes.
La comprehension scientifique courante ne nous permet pas
Ia preuve fournie dans un seul ouvrage
encore dinterprØter
coherent. II est encore plus frustrant de ne pas pouvoir tirer des
conclusions dØfinitives en ce qui concerne les problŁmes de risque
possible ou de proposer des recommandations scientifiques claires
en vue
lopØrateur
.
des animaux et des personnes qui dØmontrent
clairement que des champs magnØtiques basse frequence peuvent
avoir une interaction et produire des changements dans es
systØmes biologiques. Alors que Ia plus grande partie de cet
etudes rØalisØes
es
a suivre
procedures
Disposer
4.
-
.
strategies
SECURITE
Code Ølectrique du Canada, partie 1, CSA Standard C22. 1, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard,Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Protection,
ANSI
Occupation
Standard
Standards Institute, 1430
And Educational
Z87.1,
Broadway,
from
Eye
American
And Face
National
New York, NY 10018.
OM-184 227
Page
5
SECTION 2- INSTALLATION
2-1.
Specifications
Output
Frequency
S
Amperes Input at
Rated Load Output
Required
Output
Rated
50
Reflective
or
60
Hz,
460V
10 To 50 kHz
*While
25kWAt
100% Duty
Cycle Max
750 A (RMS),
700 V (RMS)
-
KW
KVA
Length: 31 in
(787 mm)
39
2.5 To 50
~th
30.8
0.29*
27.19
Width: 16 in
120 lb
(406 mm)
Height: 27 in
(686 mm)
(54 kg)
idling
WARNING
a
HIGH-FREQUENCY RADIATION can interfere with radio
and communications equipment.
Have
j
~-~~iJ
~
The
only qualified
user
is
person familiar with electronic
responsible
for
having
a
qualified
equipment perform
electrician
promptly
navigation, safety services, computers,
this installation.
correct any interference
problem resulting
from the
installation.
If notified
by
the FCC about
Have the installation
Keep high-frequency
2-2.
Weight
Overall Dimensions
Three-Phase
Inductance
regularly
source
Connecting Head/Coil
r!1 ~
interference, stop using the equipment
at once.
checked and maintained.
doors and
panels tightly
shut.
to Power Source
2
Corinecflng
Block
Tools Needed:
7/1 6 in
Ref. ST-801 826-C
S
OM-184 227
Page
6
2-3.
Remote 14
Receptacle RC14
Information and Connections
1
Front Panel
2
Plug
3
Threaded Collar
4
Keyway
5
Remote 14
RC14
To
connect
to
receptacle, align
plug, and tighten
Receptacle
(See Section 2-4)
keyway,
insert
threaded collar.
4
5
sb7. 1
2-4.
*
3/93
-
Ref. S-0004-A / Ref. S-0750 / Ref. ST-801 826-C
Remote 14 Socket Information
REMOTE 14
Socket Information
Socket
A
+24 volts dc.
B
Contact closure to A
C
Command reference; +10 volts dc.
D
Control circuit
Remote Contactor
Remote
Output Control
Power Source Limit
24 volts dc contactor control circuit.
common.
.
command
E
Input
G
Not used.
signal (potentiometer
wiper
or
0 to +10 volts
Absence of internal contact closure between F and J
F ~
H
Remote
completes
signals power
source
failure to remote
control device.
Coil loss
compensation
value.
I
Actual
L
Average power output signal (1 voltl5 kW).
M
Voltage output signal RMS (1 volt/i 00 volts).
N
Current output
K
Chassis
Metering
dc).
frequency output signal (1 volt/lO kHz).
signal
RMS
(1 volt/i 00 amperes).
common.
OM-i84 227
Page
7
Connecting Input
2-5.
Power
Tools Needed:
c:-::~:::::J===tj
zr
3/8 in
5/16 in
Ref. ST-801 825-C
.
Have
only qualified persons
make
this
Remove wrapper.
1
state, and local electrical codes. Route input
power cord through strain relief
to fuse block.
installation.
Line Disconnect Device Of
Proper
Rating
5
on rear
panel
Strain Relief Connector
Insert conductors
through
strain relief.
Obtain and install line disconnect device.
2
Fuse Block Cover
Remove fuse block
cover.
3
Input Conductors
4
Grounding
Conductor
Select size and length using Section 2-6.
Conductor rating must comply with national,
Fuse Block
6
Input
7
Power Source Ground Terminal
Install and connect
grounding conductor and
input conductors in conduit or equivalent to
deenergized line disconnect device.
Connect
grounding
then line
Be
grounding conductor goes
ground.
sure
earth
Tighten
strain
9
to fuse block.
Select type and size
into
to an
cover.
relief, and reinstall wrapper.
Connect grounding conductor to ground
terminal first. Then connect input conductors
Disconnect Device Ground Terminal
first,
conductors.
Reinstall fuse block
8
conductor
input
Overcurrent Protection
deenergized
(fused disconnect
using Section 2-6.
line
switch
disconnect
Install
device
shown).
.
OM-184 227
Page
8
2-6.
Electrical Service Guide
460
Input voltage
Input Amperes
At Rated
39
Output
Max Recommended Standard Fuse Or Circuit Breaker
Mm
Input Conductor Size
Max Recommended
Mm
Grounding
Rating
In
60
Amperes
In AWG/KcmiI
Input Conductor Length
8
In Feet
248
(Meters)
Conductor Size In AWGfKcmiI
Reference: 1993 National Electrical Code
(76)
10
I
s~oo~j
(NEC).
SECTION 3-OPERATION
3-1.
Controls
1
Use
Power
between
3
Adjust
control
Control
select
to
the
minimum
power
and
maximum output of the power
source. The numbers around the
control are in kilowatts (k~.
2
Use
Remote Power Control
Switch
switch
controlling
For
front
to
unit
select
way
of
output.
panel control,
position.
place
switch in Panel
For remote control,
Remote
14
controller
or
Remote
14
Section
3
place switch in
position. Connect
pendant control to
(see
receptacle
2-3).
Power Switch With Indicator
Light
Use switch to turn unit, fan motor,
and indicator light On and Off.
Unit is ready to heat 10 seconds
after Power switch is placed in On
position.
Ref. ST-801 826-C
OM-184 227
Page
9
SECTION 4- MAINTENANCE & TROUBLESHOOTING
Routine Maintenance
4-1.
A
Disconnect power
Maintain
before
during
maintaining,
more
severe
often
conditions.
3 Months
Clean
and tighten
outputconnections.
Repair
or
replace
cracked
and cords.
cables
~,~/#/
~
....+
~
6 Months
Replace damaged
Blow
or
unreadable labels.
out
or
vacuum
inside.
Overheating
4-2.
Thermostats TP1, TP2, and TP3 protect the unit from damage due to overheating. If one or more of the heat sinks get
too hot, TP1, TP2, and/or TP3 opens and output stops. The fan keeps running to cool the heat sink(s). Wait several
minutes before
trying
to heat.
Automatic Shutdown Protection
4-3.
automatically shuts down upon sensing certain fault conditions, such as an out-of-range frequency condition,
short circuit load condition, or an open circuit (no load) condition. The unit also has automatic voltage limiting and
power ratio limiting, which limits the output power based on improper load impedance.
This unit
4-4.
Safety
.
Interlock Switch
1
Rear Panel
2
Safety Interlock Switch
The
safety
prevents
energizing
the
interlock
contactor
switch
from
with the wrapper off the
unit.
.
Tools Needed:
cI::::::J===:~n
3/8 in
Ref. ST.801 826-C
OM-184 227
Page
10
4-5.
Measuring Tuning Capacitor Voltage
A
remain
Significant
capacitors
DC
check ALL
capacitors as shown to be
have discharged before
they
working on
sure
voltage
can
after unit is Off.
unit.
on
Always
Turn
Off
power
disconnect
source
and
input power.
Remove wrapper.
1
Tuning Capacitor
Cl
2
Tuning Capacitor
C2
3
Tuning Capacitor
C3
4
Voltmeter
Check
tuning capacitors.
Measure the dc
positive
(+)
voltage across the
negative (-)
and
terminals every 30 seconds until
voltage is near 0 (zero) volts.
Proceed with job inside unit.
Reinstall wrapper when finished.
Top
View
Tools Needed:
c::::=:1:====4i
3/8 in
Ref. ST-801 826-A
OM-184 227
Page
11
4-6.
Optional Ground
Fault Protection
protection circuitry
Ground fault
shuts down power
output if a potentially
automatically
source
hazardous condition exists at the
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
heating
circuit).
ground lead provided with
option must be connected
between the workpiece and
power source to provide proper
ground fault protection from a
The
this
short in the
Power Source
2
Receptacle
3
Plug
To connect
2
output circuit.
1
plug, align key with key-
way, insert end into receptacle,
and rotate plug until tight.
3
4
Handle
5
Magnet
6
Workpiece
Use handle to
place magnet on the
workpiece.
.
Ref. ST-801 826-c I Ref. 801 828-C
.
OM-184 227
Page
12
4-7.
Measuring
Input_Capacitor Voltage
A Significant
capacitors
DC
voltage
can
remain
after unit is Off.
Turn
Always
capacitors as shown to be
sure they have discharged before
working on unit.
check ALL
Off
power
on
disconnect
and
source
input power.
Remove wrapper.
1
Input Capacitor C2
2
Input Capacitor
Cl
3
Input Capacitor
C4
4
Input Capacitor
03
5
Voltmeter
Check
input capacitors.
Measure the dc voltage across the
positive (+) and negative (-)
terminals every 30 seconds until
voltage
is
near
0
(zero)
volts.
inside unit.
Reinstall wrapper when finished.
Proceed
with
job
Tools Needed:
cT~~J====in
3/8 in
Ref. ST-801 826-A
OM-184 227
Page
13
4-8.
Diagnostic
LEDs
1
Diagnostic
LEDs
diagnostic LEDs to determine
operating condition of power
Use
source.
2
~IiI
Current Source
Limit: 11OA
Fault: 115A
3
Over
Frequency
Limit: 50 kl-Iz
Fault: 55 kHz
4
Under
Frequency
Limit: 10 kHz
00
Fault: 5 kHz
5
Current
Reactive Limit: 700 A
6
Tank
Voltage
Limit: 670 V
Fault: 1100 V Peak
7
Line
Voltage
Fault: –20 %
8
Contactor
when
Lights
energized.
9
LIMIT
FAULT
O
2
CURRENT
SOURCE
10~
o
Temp
Lights when contactor is energized
and over temperature condition is
present. Also indicates top cover is
10
Tank Current
Fault Value Preset At
11
OVER
FREQUENCY
is
removed from unit.
3
o
Over
contactor
Ground Fault
Factory
(Optional)
Lights when the ground fault
circuitry detects a short in the
4
circuit
between
output
workpiece and power source.
UNDER
the
5
CURRENT
o
TANK VOLTAGE
LINE VOLTAGE
9~
8
CONTACTOR
OVER TEMP
11~
GROUND FAULT
Ref. ST-801 826-B
S
OM-184 227
Page
14
Troubleshooting
4-9.
r,i~H4r~!kH
Remedy
Trouble
No heat
output.
line fuse
Secure head/coil
connecting plate
Check and
replace
Connect power
No heat
output;
Safety
fan motor continues to
reset circuit breaker.
Replace building
or
connecting
to power source
Power switch if necessary.
source
to proper
input voltage
check for low line
or
interlock switch open. Reinstall wrapper
(see
Section
run.
Thermostat(s) TP1, TP2, and/or TP3 open (overheating).
when the unit has cooled (see Section 4-2).
Low heat
output.
4-10.
Tuning Chart
Check
tuning
Energizing
A
of induction
Current
(Amperage)*
voltage.
4-4).
Allow fan to run; the
thermostat(s)
will close
heating output system.
contactor without all 3
DO NOT operate power
Voltage*
(see Section 2-2).
block
source
tuning capacitors
without all 3
in
output circuit will damage power
tuning capacitors
in
output circuit.
Corrective Action
Frequency (KHz)
High
Low
Low
Lower inductance
High
Low
High
Add
High
Low
Mid-Range
Low
High
Low
Low
High
High
or
decrease
matching
transformer turns ratio
capacitance
Decrease
Lower
matching transformer
turns ratio and add
capacitance
capacitance
Increase
matching transformer
turns
ratio,
or
lower
capacitance
and increase inductance
Low
*High voltage
High
>
650 V rms; Low
voltage
Mid-Range
<
400 V rms;
Operating
Increase
matching transformer
turns ratio and lower
capacitance
current range: 0 to 700 A rms
OM-184 227
Page
15
SECTION 5- ELECTRICAL DIAGRAM
I
R2
SRi
+
II
LO
i
~
C
PC3
ONLY
LO
I
___________
_____________
____________________
CURRENT SOURCE INTERCONNECT
I
RCI/PL023
WI
I
__________________________________________________________________________
Ii
11W
LIOUT
~
~L1
12
01
~
IRY
JOar
24V
PLG1RO/RCIOO
~
/2
I
~
~
1C4
~.C2
A
/
av
J/D
,I!~J
____________
18v
~
CR)~
~2
<< RCI1O
1j
<<Rdi
___________
/8~(RC1~6
N
I
RG5O/PL050
+1
I I
+
I
cONTACTOR
<Rc2
_________________
I~
~
~<
RCI-4>~~
1
RC7-I I
~6-8
-
>~-~-
__________
~6-5
~
RCI6
I
LTh17
~
RC2/PLG31
RC3/PIG3O
~l~M
<RCI-3
RC1-4
~
Mull
~
Ii
_____________________________________________
I
I
I
I
I
I
~
OP11O~L
I
I
I
pci
CURRENT
I
RC17
1
3
I
Rd1/PW1I
RC2/9L012
RC3/PLG13
RC4flI.014
I
L___~~
SOURCE
CONTROL
RC63
rj
~
RC3_lj1M~
RC5JPLG15
RC6/PLO1B
RC7/PLCIY
~A
>~
RdR-1O).~
RCS-2
>~
RC54
>>
~
4
~
lR9~
RES6
p
I
Rc2-7
RC3-3
Rd3-4
RC 14
B
RC2-5
>_
+24
21
>~~---4
>>~
>>-&~~
RdB
alu
UMIT
42<4:
I~
95
~.4z
RC7-4
Rd72
B~
Rd-i
RESET
>>_~-~---
>
RC2-3
RC2-1O>)--4~----RCI-12
PC2
RC2-2
R2-12>~E~
RCl-15>>--4-
+10
~
Rd22
dOMWiID
>><E-~
< RdI7
F4
~
F5
RC1-2
LAIdH
24
+24
BRIDGE CONTROL
I
RCR1
RC1/PLGI
Rd2/PI.02
Rd47
Rd3/PLG3
WIlT 2
H
17
~
RC2R
FREQ
(1V/lOlGIz)
94,M
(1V/~(~~
Rd4/P%.04
H~4-1~)
Rd5/PLC5
Rt4-l
RC6/PLO1
Rd7/PL07
Rd48
49
,
I
RC~3
RC29
/
l~
>
10>)RC21
t.
JM
RC45>>
v~
(1V/I0~)
~
~
(1V/BX14)
52
N
>
K
>
RC22
T~<
I
Rd-I
RC24
>>
Rc5-3>~
I
~
RC3_lO>L
~
01ff
/
PORSR
I
L~ar__~_<<
R037
>>~
RO3-2
~
Rd3-I
>>
RO3-6
>>~
PANEL
RC2-1 I
E
>
~-O
I
01ff
I
Figure
OM-184 227
Page
5-1. Circuit
I
~
I
I
~-
~/7
I
Diagram
16
drawrna#
zi
(RE)R McOULE)
Cl
c2El
PC4
A2
BRIDGE INTERCONNECT
Cl
(FRONT UODUI~D
If)7
197 852
OM-184 227
Page
17
SECTION 6- PARTS LIST
117 Hardware is
common
and
not available unless listed.
Fig.
62
21
ST-8O~ 828-C
Figure
6-1. Main
Assembly
S
OM-184 227
Page
18
BASE
BLOCK,
BRACKET,
NPANEL,
KNOB
LENS,
SCLIP,
RNUT,
LABEL,
CABLE,
LED,
HANDLE
MAGNET,
PLUG,
ETACAMENPDT-LAOCFTLE,
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
1
179245..
2
Figure
6-2
+179246..
3
147876
195830
124886
...CR1
000 174
179231
S3
603 946
10...
184698
11
186441
178563
.13...
145743
14
179235
15
Fl -3
*184 700
16
184696
184701
17
18
FM2
PLG26....
120376
26
171 007
27
159036
30
180894
159035
PC6
196854
31
115443
32
106702
33
127837
197869
35
197900
36
197854
37
198035
38
197931
39
127836
+When
ordering
*Recommended
a
1
1
1
1
1
1
1
FUSE, semiconductor 50A 500V
fuse semiconductor modular
3
side RH
1
1
1
1
1
number)
1
SWITCH, rocker SPDT 4A 25OVAC
1
12
LED clear
1
CIRCUIT CARD, diagnostic display
retainer lens
CIRCUIT CARD ASSY, ground fault control
no 6-32 x .750 Ig .250 hex
12
1
4
4
006-32 .31 hex .20h sti pld
tw 1k insul fern
1
1
ground fault
work ground
1
red 2.1 V 20 mA 45.0 mcd
1
1
1
permanent
1
tw 1k insul male
component originally displaying
Spare
1
1
159039
PC5
1
front
SWITCH, rocker SPDT l5A 125VAC
(order by model and serial
179232
29
1
1
24
28
1
POTENTIOMETER, cp std slot lIT 2W 10K ohm
RECEPTACLE w/SOCKETS
143976
S2
2
1
RC14
25
1
LABEL, warning general precautionary
COVER, fuse block
CONTACTOR, def purpose 60A 3P 24V
RELAY, end 24VAC 3PDT
PANEL, rear
SWITCH, mag blwt lim 1OA 125/25OVDC
CABLE, pwr 1 2ft 8ga 4/c
BUSHING, strain relief
NUT, nylon
LUG, Univ w/scr 600V
1
21
51
1
WRAPPER
CONNECTOR & SOCKETS
fan mtg small
073 562
23
1
135635
Rl
....
PANEL, side LH
CENTER BAFFLE ASSEMBLY
MOTOR, fan 24VDC
20
22
Assembly
184702
184845
19
6-1. Main
Quantity
a
precautionary label, the label should also be ordered.
Parts.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-184 227
Page
19
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
.
..
.
..
.
..
.
..
1
2
3
4
..
5
.
..
6
.
..
.
7
PM1,2
PLG21,22
..
.
TP1-3
..
...
...
.
SRi
PC3
PLG23.
..
8
.
.
...
...
PCi
...
PLG11,15
..
.
IGBTw/CIRCUITCARDASSEMBLY
2
.
CONNECTOR & SOCKETS
2
.
.
1
173 630
.
.
181 170
.
.
THERMOSTAT,NC
DIODE, power module/scr 75A 1600V
CIRCUIT CARD, current source interconnecting
131 204
.
.
.
.
184 840
.
.
135 635
.
.
155 748
.
.
178 064
.
.
.
.
.
.
.
.
.
.
.
.
115 091
115 092
PLG14.
131 204
...
.
098 376
PLG12
PLG16.
PLG17.
2)
.
*012 658
CT1
...
6-1 Item
.
115 094
006 334
...
F4,5
...
PLG13.
.
.
Assembly (Fig
.
188 190
...
6-2. Center Baffle
Quantity
...
131 056
...
130 203
1
1
.
CONNECTOR & SOCKETS
FUSE, mintr gI slo-blo 2A 250V
HOLDER, fuse mintr
2
TRANSFORMER,
1
current
1
1
primary
CONNECTOR & SOCKETS
BUS BAR, lem
1
CIRCUIT CARD, current source control
CONNECTOR & SOCKETS
1
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
1
1
& SOCKETS
& SOCKETS
& SOCKETS
& SOCKETS
1
1
1
1
19
Hardware is
common
and
not available unless listed.
15
13
12
23
41
ST-aol 832-A
Figure
OM-184 227
Page
20
6-2. Center Baffle
Assembly
.
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
179233
..
10.... Li
180 114
..
L2
182 563
..
12... CT2
i84 842
..
13... CT3
184 841
..
PC4
181 175
..
179 220
..
16
179 239
..
17
186 523
..
ii
....
14...
15... C5-7
....
18
192 515
..
19... CT4
185 935
..
20
196 245
..
21
196 247
..
22
196 246
..
23
179 238
..
24
+179 236
..
25
126 026
..
26.... Zi
180 115
..
179234
..
28... PC2
177 753
..
28... PC2
196 541
..
131 052
..
...27
PLG1
PLG2
PLG3
PLG4
PLG5
PLG6
PLG7
....
130 203
....
115 091
..
..
131 056
..
131 204
..
115 092
..
115 093
..
29
025 248
..
30
179 875
..
31
179 876
..
32..
C8, 10
....
....
....
170 867
..
C9R4/C11R3
34.. DM1,2....
179 869
..
35.... Ti
182 564
..
36.. DM3-6....
179 869
..
.33
PM3,4....
180711
..
176 421
..
38.... T2
179 870
..
PLG5O....
39... FM1
PL025....
131 055
..
182 575
..
135 635
..
40
179 872
..
41
184 844
..
174 980
..
37..
42... C1-4
....
PLG8
RC8
PLG16O
RC16O....
...
*Recommended
Spare
115 092
..
135409
..
131 052
..
188352
..
6-2. Center Baffle
Quantity
Assembly (Fig
6-1 Item
2)(Continued)
WINDTUNNELLH
1
INDUCTOR, input
INDUCTOR, series
TRANSFORMER, current bridge
TRANSFORMER, current power feedback
CIRCUIT CARD, bridge interconnecting
CAPACITOR, polyp met film 1 .Suf 1 000VDC
BUS BAR, laminated output LH
STRIP, mtg output
BRACKET, mtg output block
SENSOR, tank current
ENCLOSURE, output
TOPPLATE, output enclosure
ENDPLATE, output enclosure
BUS BAR, laminated output RH
1
1
1
1
1
3
1
2
2
1
1
1
1
1
MIDPLANE
1
LABEL, warning electric shock
2
STABILIZER
WINDTUNNELRH
CIRCUIT CARD, bridge control (used with 903 469-01 -2)
CIRCUIT CARD, bridge control (used with 903 469)
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
STAND-OFF, insul .250-20
BUS BAR, diode RH
BUS BAR, diode LH
CAPACITOR,
polyp
x
1
1
1
1
1
1
4
1.250
2
2
film 1 .5uf 1 000VDC
2
SNUBBER
2
DIODE, ultrafast recovery 100A 1200V
TRANSFORMER, HF
DIODE, ultra fast recovery 1 OOA 1 200V
TRANSISTOR, IGBT module 150A 1200V
TRANSFORMER, control
2
1
4
2
1
CONNECTOR & SOCKETS
MOTOR, fan 48VDC
1
CONNECTOR & SOCKETS
1
BRACKET, mtg capacitor
BRACKET, fan mtg
CAPACITOR, elect 2700ufd 42OVDC
1
4
CONNECTOR & SOCKETS
1
CONNECTOR&PINS
CONNECTOR&SOCKETS
CONNECTOR&PINS
1
1
1
1
Parts.
precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
+When
ordering
a
component originally displaying
a
OM-184 227
Page
21
Notes
S
S
Miller
SERVICE VIDEOS
SERVICE TRAINING
FROM MILLER ELECTRIC
These Service Videos will
help you
-
learn about main
tenance, troubleshooting, and servicing specific Miller
equipment.
Also, if you are a Miller Certified Service Technician,
these videos can help you recertify. Passing the
included test will earn five points towards the forty
points needed.
You will find each of these
professionally produced
videos to be very informative and
your Service Video Library.
U
U
U
(#197 007)
1j
videos
(#197 009)
U
324-1016
$3.00
324-1014
$86.00
324-1031
$86.00
324-1018
$3.00
324-1032
$86.00
Additional Deltaweld Test Sheet
(#197 011)
324-1019
$3.00
324-1017
Payment Information
or
Money Order
Send check
or
money order
payable
to:
Neenah
Printing
Attn: Literature Distribution Center
P0. Box 506
Neenah, WI 54957-0506
Mastercard
Purchase Order
Visa
_________________
Name of Card holder
_____________________________________
Account #__________________________________
Cardholders
Exp.
Date
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
60M)
$126.00
Additional S-MM Test Sheet
Check
S-62& S-54 &
Deltaweld 452 Video Kit
(#197 010)
U
(#197 017)
-
324-1009
Additional Bobcat 225 NT Test Sheet
$86.00
324-1030
S-64M Video Kit
(#197 015)
(2
Bobcat 225 NT Video Kit
Additional S-62 & S-64 Test Sheet
(#197 014)
U
Package
(#197 006)
$3.00
324-1008
S-62 & S-64 Series Video Kit
(#197 012)
1J
Feeder Series
$86.00
324-1035
Additional XMT 304 Test Sheet
(#197 019)
U
valuable part of
XMT 304 Video Kit
(#197 018)
U
a
Customer #
$3.00
Miller
WELDING EQUIPMENT
SEPVICE ENGINEERING
SELF-PACED
TRAINING COURSE
FROM MILLER ELECTRIC
-
Learn the basics of
Welding equipment troubleshooting
servicing With this three module course designed
for home study, industrial and educational use. This
course Will provide the basic knowledge to begin a
career in servicing welding equipment, act as a
refresher, or provide a welding salesman or technician
service and troubleshooting techniques.
and
Miller
A certificate of completion is awarded by the
Training Department upon successful completion
of the
course.
Volt-ohm Meter
Inspection
High Frequency
Safety
Load Bank
U Welding Equipment
Service
registered
Check
Symbols
Component Identification
Troubleshooting
$60.00
(#145 871)
Additional Text
(Includes
text and
registered
answer
card.)
exams, and
card.)
answer
Information
Payment
J
Electronic
Operation
Operation
U
(#145 870)
Course
Engineering Training
(Includes text, videotape,
MODULE 3
MODULE 2
MODULE 1
Visual
or
send check
Money Order
or
money order
payable
to:
Neenah
Printing
AUn: Literature Distribution Center
P0. Box 506
Neenah, WI 54957-0506
II]
I]
Purchase Order
Mastercard
Visa
______________
Name of Card holder
__________________________________________________
Account #
Cardholders
Exp.
Date
__________________________
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
Customer #
$35.00
S
S
~::L.
Effective January 1, 1999
with a serial number preface of KK
(Equipment
/
Warranty Questions7
This limited
/
or
newer)
warranty supersedes all previous Miller warranties and is exclusive with
guarantees or warranties expressed or implied.
no
other
Call
1-800-4-A-MILLER
for your local
Miller distributor
r
*
Subject to the terms and conditions
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.
LIMITED WARRANTY
below,
-
Miller Electric
Torches
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your dtstnbutor also gives
you
Service
~ou
always getthefast,
reliable .reSpOnSe:you
need. Most replacement
parts can bein your
hshds in 24 hours.
F
Support
f4eed fast anbwers
the
contact your distributor.
y..
*
Remote Controls
*
Accessory Kits
*
Replacement
*
Spoolmate
Parts
(No labor)
185
Within the
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
equipment was delivered to the original retail purchaser, or
year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent toan
Millers
True Bluefi Limited
shall not
apply
to:
by Miller, but manufactured by others,
engines or trade accessories. These items are
by the manufacturers warranty, if any.
Items furnished
1.
such
as
covered
2.
Warranty
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
the
to
tough:weldihg questions?
F!
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.
APT, ZIPCUT & PLAZCUT Model Plasma Cuffing
Theexpertl~eotthe
one
3.
Equipment
1.
distributor and Miller is
there to help %Łou, every
step of the way.
2.
5 Years Parts
Original
*
Inverters
3.
3 Years Labor
(input
and
which
Power Sources
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year
Supplies
Parts and Labor
Motor Driven Guns
(w/exception
of
Spoolmate
185)
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
RFCS Foot Controls
for operation
equipment.
used
for the
outside
of the
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers 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
risk and expense. Millers option of repair or
at customers
replacement will be P0.8., Factory atAppleton, Wisconsin, or
P0.8. 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 PERMIUED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
OR
INCIDENTAL
SPECIAL,
INDIRECT,
DIRECT,
*
IHPS Power Sources
*
Water Coolant
ANY
*
HF Units
*
Grids
Systems
Maxstar 140
*
Spot
*
Load Banks
*
SDX Transformers
*
Miller
Welders
Cyclomatic Equipment
Running Gear/Trailers
Plasma
Cuffing Torches (except APT,
Models)
ZIPCUT &
PLAZCUT
*
Options
(NOTE: Field options are covered under True
Bluefi for the remaining warranty period of the
product they are installed in, or for a minimum of
whichever is greater.)
one year
Field
6 Months
90
*
Days
Batteries
Parts
MIG Guns/TIG Torches
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
OR
GUARANTY
WARRANTY,
REPRESENTATION AS TO PERFORMANCE, AND ANY
ANY
OR
TORT
REMEDY FOR BREACH OF CONTRACT
OTHER LEGAL THEORY WHICH, BUT FOR THIS
BY
ARISE
IMPLICATION,
MIGHT
PROVISION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
TO
AND
ALL
ANY
RESPECT
WITH
PURPOSE,
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
AND
*
*
5.
been
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
4.
other
AND MAINTENANCE OF WELDING EQUIPMENT.
*
*
by any party
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
Transformer/Rectifier Power Sources
Cuffing
has
specifications
output rectifiers only)
Parts and Labor
3 Years
*
-
main power rectifiers
*
that has been modified
Miller, or equipment that has been improperty
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
than
International distributor.
ANY
IMPLIED
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
or consequential damages, so the above
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.
indirect, special
limitation
or
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_waif 9/99
~,~
0.
~
~.
.0
..:
Owners
Please
complete
:
Record
personal records.
and retain with your
Ii
Number
Serial/Style
Model Name
Purchase Date
(Date which equipment
was
delivered to
0
original customer.)
Distributor
Address
/
City
State
Zip
.0
.
L~
Resources Available
Always provide Model Name and Serial/Style Number.
/
Contact your Distributor for:
a distributor or service agency
you, call 1 -800-4-A-Miller or visit our
website at www.MillerWelds.com
To locate
Consumables
Welding Supplies and
Options
and Accessories
:0
near
Personal
.10:
Safety Equipment
0
Service and
Repair
Replacement
Miller Etectnc
Company
Spencer Street
An litnots Tool Worls
Parts
1635 West
Appleton
Training (Schools, Videos, Books)
WI 54914 USA
International
Technical Manuals
and Parts)
Circuit
Mfg Co
(Servicing Information
USA
Headquarters-USA
Phone~ 920-735-4505 Ao-Aiterded~
USA & Canada FAX: 920-735-4134.
International FAX 920 735-4125
Diagrams
furopean HeadquartersUnited Kingdom
Pt~one: 44 (0) 1204-593493
FAX: 44 (0) 1204598066
Welding Process Handbooks
www.MiHerWeIds~com
Contact the
Delivering
Carrier for:
For assistance in
filing
contact your distributor
manufacturer s
File
a
claim for loss
or
damage during
shipment.
.
settling claims,
and/or equipment
or
Transportation Department.
p//A Miller
PRINTED IN USA
'
ThThwer~fBkte.
1999 Miller Elednic
Mfg.
Go.
9/99
~