OM-184 227K
2006−05
Processes
Induction Heating
Description
Induction Heating Power Source
Intellifire 250
File: Induction Heating
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien . . . . . . . . . . . . . . . . . .
2-2. Informations concernant les champs électro-magnétiques (Information EMF) . . . . . . . . . . . . . . . . . .
2-3. PRINCIPALES NORMES DE SÉCURITÉ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Connecting Head/Coil to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Connecting 3-Phase Input Power For Models With Customer Supplied Cord . . . . . . . . . . . . . . . . . . .
3-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Automatic Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-4. Safety Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-5. Measuring Tuning Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-6. Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-7. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-8. Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-10. Tuning Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE
USING
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
safety_ihom 5/05
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y
Marks a special safety message.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
. Means “Note”; not safety related.
1-2. Induction Heating Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only a
summaryof the more complete safety information found in the
ty Standards.
D
Frequentlyinspect input power cord for damage or bare wiring − re-
place cord immediately if damaged − bare wiring can kill.
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
Do not touch power circuit if you are in contact with the work, ground,
or another power circuit from a different machine.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
During operation, keep everybody, especially children, away.
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in inverter-type
power sources after removal of input power.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
internal circuits are also live when power is on. Incorrectly installed or
improperlygrounded equipment is a hazard.
D
Do not touch live electrical parts.
FUMES AND GASES can be hazardous.
D
Enclose any connecting bus bars and coolant fittings to prevent
unintentionalcontact.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation to re-
move fumes and gases.
D
Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors,
gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or ac-
cidental contact with the workpiece or ground. For these
conditions,see ANSI Z49.1 listed in Safety Standards. And, do not
work alone!
D
D
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson near-
by. Fumes and gases from heating can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
D
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
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.
Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and while wearing an air-
supplied respirator. The coatings and any metals containing these
elementscan give off toxic fumes if overheated. See coating MSDS
for temperature information.
D
D
D
Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input pow-
er cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly grounded
receptacle outlet.
D
When making input connections, attach proper grounding
conductor first − double-check connections.
OM-184 227 Page 1
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FIRE OR EXPLOSION hazard.
INDUCTION HEATING can cause burns.
D
D
D
Do not overheat parts and adhesive.
Watch for fire; keep extinguisher nearby.
Keep flammables away from work area.
D
D
Hot parts and equipment can injure.
Do not touch or handle induction head/coil
during operation.
D
Do not touch hot parts bare-handed.
D
D
D
Do not locate unit on, over, or near combustible surfaces.
Do not install unit near flammables.
D
D
Allow cooling period before handling parts or equipment.
Keep metal jewelry and other metal personal items away from
head/coilduring operation.
Do not operate unit in explosive atmosphere.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury.
STATIC (ESD) can damage PC boards.
D
Use handle and have person of adequate
physical strength lift unit.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
D
Move unit with hand cart or similar device.
For units without a handle, use equipment of
adequatecapacity to lift unit.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D
When using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of unit.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
FLYING METAL OR ADHESIVE can injure eyes.
D
D
D
Have only qualified person familiar with electronic equipment per-
form this installation.
D
Wear approved safety glasses with side
shields or wear face shield.
The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
MOVING PARTS can cause injury.
If notified by the FCC about interference, stop using the equip-
ment at once.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut.
MAGNETIC FIELDS can affect pacemakers.
READ INSTRUCTIONS.
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near induction heating operations.
D
Read Owner’s Manual before using or servic-
ing unit.
Use only genuine Miller/Hobart replacement
parts.
D
OVERUSE can cause OVERHEATING
D
D
Allow cooling period.
Reduce output or reduce duty cycle before
starting to heat again.
D
Follow rated duty cycle.
1-4. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y
For Diesel Engines:
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and oth-
er reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
CanadianElectrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard,Rex-
dale, Ontario, Canada M9W 1R3.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
OM-184 227 Page 2
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1-6. EMF Information
ConsiderationsAbout Induction Heating And The Effects Of Low Fre-
quency Electric And Magnetic Fields
us to draw definite conclusions about questions of possible risk or to of-
fer clear science-based advice on strategies to minimize or avoid
potentialrisks.”
To reduce magnetic fields in the workplace, use the following proce-
dures:
1. Arrange output cable to one side and away from the operator.
2. Do not coil or drape output cable around the body.
3. Keep power source and cable as far away from the operator as
practical.
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields − Background Paper, OTA-
BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
peoplewhich clearly establish that low frequency magnetic fields can in-
teract with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientif-
ic understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding or induction heating operations. If cleared by your doctor, then
following the above procedures is recommended.
OM-184 227 Page 3
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SECTION 2 − MESURES DE SECURITE POUR LE
CHAUFFAGE PAR INDUCTION
ihom_fre 8/03
LE CHAUFFAGE PAR INDUCTION peut être dangereux.
AVERTISSEMENT
PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE
MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS D’UN STIMULATEUR CARDIAQUE DOIVENT
PREALABLEMENT CONSULTER LEUR MEDECIN.
Pendant les opérations de chauffage, comme dans la plupart des activités, l’opérateur s’expose à certains dangers.
Le chauffage n’est pas dangereux à condition de prendre certaines mesures. Les consignes de sécurité indiquées
ci-après ne sont qu’un résumé des informations plus détaillées se trouvant dans les normes de sécurité énumérées
à la page suivante. Lire et respecter toutes les normes de sécurité.
LES OPERATIONS D’INSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT
ETRE CONFIEES QU’A DU PERSONNEL QUALIFIE.
7. Installer et mettre cet équipement correctement à la terre
Danger de mort PAR ELECTROCUTION.
conformément au manuel utilisateur et aux codes nationaux,
Le contact de composants électriques peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de puissance et les connexions de
sortie sont sous tension lorsqu’on active la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque
l’alimentation est sur marche. Des équipements
installés ou reliés à la borne de terre de manière
incorrecte sont dangereux.
gouvernementauxet locaux.
8. Vérifier souvent la terre de l’alimentation − contrôler et s’assurer
que le conducteur de terre du câble d’alimentation est
correctement relié à la borne de terre dans le boîtier de
déconnexionou que le connecteur est branché à une sortie de
boîtier correctement mise à la terre.
9. En réalisant des connexions d’entrée brancher d’abord le
conducteur de terre approprié − contrôler deux fois les
connexions.
1. Ne pas toucher des composants électriques sous tension.
10. Vérifier souvent le bon état du câble d’alimentation ou l’isolation
des fils − remplacer le câble immédiatement s’il est endommagé −
des fils dénudés peuvent provoquer des accidents mortels.
2. Envelopper les connexions et raccords de refroidissement pour
éviter tout contact accidentel.
11. Arrêter tous les équipements lorsqu’ils ne sont pas utilisés.
3. Porter des gants d’isolation secs, sans trous, et une protection
corporelle.
12. Ne pas utiliser des câbles usés, endommagés, sous
dimensionnésou mal épissés.
4. Isolez-vous de la pièce et du sol avec des tapis ou des
couvertures d’isolation suffisamment grands pour prévenir tout
contact physique avec la pièce ou la terre.
13. Ne pas porter les câbles autour de votre corps.
14. Ne pas toucher le circuit électrique si vous êtes en contact avec la
pièce, la terre ou le circuit électrique d’une autre machine.
5. Déconnecter l’alimentation avant d’installer l’appareil ou d’en
effectuer l’entretien. Verrouiller ou étiqueter la sortie
d’alimentation selon la norme OSHA 29 CFR 1910.147
(se reporter aux Principales normes de sécurité).
15. Utiliser seulement des équipements bien entretenus. Réparer ou
remplacer immédiatement des composants endommagés.
Effectuer des travaux d’entretien sur l’appareil selon le manuel.
16. Porter un harnais de sécurité pour effectuer des travaux
au-dessus du sol.
6. Utiliser seulement des tuyaux non conducteurs avec une
longueurminimale de 460 mm pour assurer l’isolement.
17. Maintenir solidement en place tous les panneaux et couvercles.
1. Ne pas toucher ou manipuler la tête/l’enroulement à induction
pendantle fonctionnement.
2. Tenir les bijoux et autres objets personnels en métal éloignés de
la tête/de l’enroulement pendant le fonctionnement.
3. Laisser refroidir les composants ou équipements avant de les
manipuler.
LE CHAUFFAGE PAR INDUCTION peut
provoquer des blessures ou des
brûlures au contact de PIECES
CHAUDES OU DE L’EQUIPEMENT.
La mise en place de l’appareil sur, au-dessus ou à
proximité de surfaces inflammables peut être source
d’INCENDIES OU d’EXPLOSION.
LE CHAUFFAGE PAR INDUCTION peut
provoquer un incendie.
1. Ne pas surchauffer les composants ni les
adhésifs.
1. Ne pas placer l’appareil sur, au-dessus ou à proximité de
surfaces infllammables.
2. Ne pas installer l’appareil à proximité de produits inflammables
2. Attention aux risques d’incendie: tenir un
extincteur à proximité.
3. Stocker des produits inflammables hors de la
zone de travail.
3. Ne pas faire fonctionner l’appareil en atmosphère explosive.
OM-184 227 Page 4
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5. Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz
provenantdu 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.
DES FUMEES ET DES GAZ peuvent
être dangereux pour votre santé.
Le chauffage à induction génère des fumées et des
gaz. Leur inhalation peut être dangereuse pour votre
santé.
6. Ne pas chauffer dans des endroits se trouvant à proximité
d’opérationsde dégraissage, de nettoyage ou de pulvérisation. La
chaleur peut réagir en présence de vapeurs et former des gaz
hautementtoxiques et irritants.
1. Eloigner la tête des fumées. Ne pas respirer les fumées.
2. A l’interieur, ventiler la zone et/ou utiliser un extracteur pour
l’évacuationdes fumées et des gaz.
3. Si la ventilation est insuffisante, utiliser un respirateur à
alimentationd’air homologué.
4. Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les adhésifs, les métaux, les
consommables, les revêtements, les nettoyants et les
dégraisseurs.
7. Ne pas chauffer des métaux munis d’un revêtement tels que l’acier
galvanisé, plaqué au plomb ou au cadmium, à moins que le
revêtement ne soit enlevé de la zone chauffée, que la zone soit
bien ventilée et, si nécessaire, en portant un respirateur. Les
revêtements et tous les métaux contenant ces éléments peuvent
dégager des fumées toxiques s’ils sont chauffés.
2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien
LA CHUTE DE MATERIEL peut provoquer
des blessures personnelles graves et en-
dommager les équipements.
UNE UTILISATION INTENSIVE peut provo-
quer un SURCHAUFFEMENT DU MATERIEL.
1. Prévoir une période de refroidissement
2. Réduire le courant de sortie ou le facteur de marche
avant de recommencer le chauffage.
1. Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever
l’appareil.
3. Respecter le facteur de marche nominal.
2. Déplacer l’appareil à l’aide d’un charriot ou d’un
engin similaire.
L’ELECTRICITE STATIQUE peut endomma-
ger les composants des tableaux électri-
ques.
3. Pour les appareils sans poignée utiliser un équipe-
ment d’une capacité appropriée pour soulever
l’appareil.
1. Etablir la connexion avec la barrette de terre avant
de manipuler des cartes ou des pièces.
2. Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
4. En utilisant des fourches de levage pour déplacer
l’unité,s’assurer que les fourches sont suffisamment
longues pour dépasser du côté opposé de l’appareil.
Il subsiste DU COURANT CONTINU IMPOR-
TANT après la mise hors tension de l’alimen-
tation électrique.
1. Avant de toucher des organes internes, arrêter la
source électrique, débrancher l’alimentation, et dé-
charger les condensateurs d’alimentation conformé-
ment aux instructions indiquées dans la partie main-
tenance.
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 latérales.
LE RAYONNEMENT HAUTE FREQUENCE
peut provoquer des interférences avec les
équipements de radio-navigation et de com-
munication, les services de sécurité et les or-
dinateurs.
• Demander seulement à des personnes qualifiées
familiarisées avec des équipements électroniques
de faire fonctionner l’installation.
DES
ORGANES
MOBILES
peuvent
provoquer des blessures.
1. S’abstenir de toucher des organes mobiles tels que
des ventilateurs.
2. Maintenir fermés et fixement en place les portes, pan-
neaux, recouvrements et dispositifs de protection.
• L’utilisateurest tenu de faire corriger rapidement par
un électricien qualifié les interférences résultant de
l’installation.
DES CHAMPS MAGNETIQUES CREES PAR
DES COURANTS ELEVES peuvent affecter le
fonctionnement du stimulateur cardiaque.
• Si le FCC signale des interférences, arrêter immé-
diatement l’appareil.
• Effectuer régulièrement le contrôle et l’entretien de
1. Porteurs de stimulateur cardiaque, restez à distance.
l’installation.
2. Les porteurs d’un stimulateur cardiaque doivent d’a-
bord consulter leur médecin avant de s’approcher
des opérations de chauffage à induction.
• Maintenir soigneusement fermés les portes et les
panneaux des sources de haute fréquence.
OM-184 227 Page 5
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2-2. Informations concernant les champs électro-magnétiques (Information EMF)
Considérationsrelatives au chauffage à induction et aux effets des
champs électriques et magnétiques basse fréquence.
proposer des recommandations scientifiques claires pour des
stratégies à suivre en vue de minimiser ou de prévenir des risques
potentiels.”
Le texte suivant est extrait des conclusions générales Département
du Congrès U.S., Office of Technology Assessment, Effets
biologiques des champs magnétiques et électriques basse
fréquence − Background Paper, OTA-BP-E-53 (Washington, DC:
U.S. Government Printing Office, May 1989): “. . . on dispose
maintenant d’importantes découvertes scientifiques reposant sur
des expériences effectuées dans le domaine cellulaire et des études
réalisées sur des animaux et des personnes qui démontrent
clairementque 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’interpréterla preuve fournie dans un seul ouvrage cohérent. Il est
encore plus frustrant de ne pas pouvoir tirer des conclusions
définitivesen ce qui concerne les problèmes de risque possible ou de
Pour réduire les champs magnétiques sur le poste de travail,
appliquerles procédures suivantes :
4. Disposer le câble de sortie d’un côté à distance de l’opérateur
5. Ne pas enrouler ou draper le câble électrique autour du corps.
6. Placer la source de courant et le câble le plus loin possible de
l’opérateur.
En ce qui concerne les stimulateurs cardiaques
Les procédures ci-dessus concernent également les porteurs de
stimulateurcardiaque. Consulter votre médecin pour un complément
d’information.
2-3. PRINCIPALES NORMES DE SÉCURITÉ
Normes de sécurité et de santé, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington,D.C. 20402.
Code électrique du Canada, partie 1, CSA Standard C22.1, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard,Rexdale,Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Code électrique national, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-184 227 Page 6
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SECTION 3 − INSTALLATION
3-1. Specifications
Amperes Input at
Rated Load Output 50
or 60 Hz, Three-Phase
Required
Reflective
Inductance
Output
Rated Output
Frequency
Overall Dimensions
Weight
460 V
KVA
KW
Length: 31 in
(787 mm)
Width: 16 in
(406 mm)
Height: 27 in
(686 mm)
25 kW At
100% Duty
39
0.29*
165 lb
(75 kg)
10 To 50 kHz
*While idling
Cycle − Max
750 A (RMS),
700 V (RMS)
2.5 To 50 μh
30.8
27.19
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,
computers, and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut.
3-2. Connecting Head/Coil to Power Source
1
2
Rear Panel
1
Connecting Block
2
. Do Not Exceed 58 in lb
.
(6.6 N m) of torque when
making connections.
Tools Needed:
7/16 in
Ref. ST-801 826-C
OM-184 227 Page 7
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3-3. Remote 14 Receptacle RC14 Information and Connections
1
2
3
4
5
Front Panel
Plug
1
Threaded Collar
Keyway
Remote 14 Receptacle RC14
To connect to receptacle, align key-
way, insert plug, and tighten
threaded collar.
4
A
J
5
K
I
B
C
L
N
H
M
D
G
F
E
3
2
sb7.1* 3/93 - Ref. S-0004-A / Ref. S-0750 / Ref. ST-801 826-C
3-4. Remote 14 Socket Information
Socket
Socket Information
+24 volts dc.
A
B
Remote Contactor
Contact closure to A completes 24 volts dc contactor control circuit.
Command reference; +10 volts dc.
Control circuit common.
C
D
E
G
Remote Output Control
Power Source Limit
Input command signal (potentiometer wiper or 0 to +10 volts dc).
Not used.
Absence of internal contact closure between F and J signals power source failure to remote
control device.
F, J
Coil loss compensation value.
H
I
Actual frequency output signal (1 volt/10 kHz).
Average power output signal (1 volt/5 kW).
Voltage output signal RMS (1 volt/100 volts).
Current output signal RMS (1 volt/100 amperes).
Chassis common.
L
Remote Metering
M
N
K
OM-184 227 Page 8
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3-5. Connecting 3-Phase Input Power For Models With Customer Supplied Cord
Y
Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
Y
Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
3
Y
Y
Make input power connections to
the welding power source first.
= GND/PE Earth Ground
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
9
8
See rating label on unit and check input
voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
11
10
Select size and length of conductors using
Section 3-6. Conductors must comply with
national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
4
Welding Power Source Input Power
Connections
7
2
Strain Relief
Route conductors (cord) through strain re-
lief and tighten screws.
3
Fuse Block Cover
Remove fuse block cover.
4
5
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
groundingterminal first.
6
Welding Power Source Line
Terminals
1
7
Input Conductors L1 (U), L2 (V) And
L3 (W)
Connect input conductors L1 (U), L2 (V)
and L3 (W) to welding power source line
terminals.
2
Install fuse block cover. Install welding
power source wrapper.
7
Disconnect Device Input Power
Connections
4
5
3
6
8
Disconnect Device (switch shown in
OFF position)
9
Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
10 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V)
And L3 (W) to disconnect device line
terminals.
Tools Needed:
5/16 in
3/8 in
11 Over-Current Protection
Select type and size of over-current
connect switch shown).
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
803 766-A / Ref. ST-801 825-C
OM-184 227 Page 9
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3-6. Electrical Service Guide
60 Hz Three Phase
Input Voltage
460
39
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Time-Delay
1
2
3
45
60
8
Normal Operating
4
Min Input Conductor Size In AWG
287
(87)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG
10
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Consult factory for circuit breaker applications.
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.
SECTION 4 − OPERATION
4-1. Controls
3
1
4
2
Ref. ST-801 826-C
1
Power Adjust Control
For remote control, place switch in Remote 14
position. Connect controller or pendant control
3
Power Switch With Indicator Light
Use control to select power between the mini-
mum and maximum output of the power
source. The numbers around the control are in
kilowatts (kW).
Use switch to turn unit, fan motor, and indica-
tor light On and Off.
The remote control functions as a slave to the
front panel Power Adjust control. For example,
if the front panel control is set to 12.5 kW and
the remote control is set to maximum, output
will be 12.5 kW. To obtain maximum output
Unit is ready to heat 10 seconds after Power
switch is placed in On position.
2
Remote Power Control Switch
Use switch to select way of controlling unit out-
put.
For front panel control, place switch in Panel from the unit using a remote control, the front
position.
4
Ground Fault Test Switch
panel control must be set to maximum.
Use switch to test ground fault circuitry.
OM-184 227 Page 10
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SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Clean and tighten
output connections.
Repair or replace
cracked cables
and cords.
6 Months
Replace damaged or
unreadablelabels.
Blow out or vacuum
inside.
5-2. Overheating
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.
5-3. Automatic Shutdown Protection
This unit 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.
5-4. Safety Interlock Switch
1
2
Rear Panel
1
Safety Interlock Switch
The safety interlock switch
prevents the contactor from
energizingwith the wrapper off the
unit.
2
Tools Needed:
3/8 in
Ref. ST-801 826-C
OM-184 227 Page 11
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5-5. Measuring Tuning Capacitor Voltage
Y
Significant AC voltage can remain on
Turn Off power source and
disconnect input power.
capacitors after unit is Off. Always
check ALL capacitors as shown to be
sure they have discharged before
working on unit.
Remove wrapper.
1
2
3
4
Tuning Capacitor C1
Tuning Capacitor C2
Tuning Capacitor C3
Voltmeter
4
Check tuning capacitors.
Measure the ac voltage across the
terminals on capacitors every 30
seconds until voltage is near 0
(zero) volts.
Proceed with job inside unit.
Reinstall wrapper when finished.
1
2
3
Top View
Tools Needed:
3/8 in
Ref. ST-801 826-A
OM-184 227 Page 12
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5-6. Ground Fault Protection
Ground fault protection circuitry
automaticallyshuts 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).
1
The supplied ground lead must be
connectedbetween the workpiece
and power source to provide
proper ground fault protection
from a short in the output circuit.
1
2
3
Power Source
Receptacle
Plug
To connect plug, align key with key-
way, insert end into receptacle, and
rotate plug until tight.
2
4
5
6
Handle
Magnet
3
Workpiece
Use handle to place magnet on the
workpiece.
4
6
5
Ref. ST-801 826-C / Ref. 801 828-C
OM-184 227 Page 13
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5-7. Measuring Input Capacitor Voltage
Turn Off power source and
disconnect input power.
Y
Significant DC voltage can remain on
capacitors after unit is Off. Always
check ALL capacitors as shown to be
sure they have discharged before
working on unit.
Remove wrapper.
1
2
3
4
5
Input Capacitor C2
Input Capacitor C1
Input Capacitor C4
Input Capacitor C3
Voltmeter
Check input capacitors.
Measure the dc voltage across the
positive (+) and negative (−)
terminals every 30 seconds until
voltage is near 0 (zero) volts.
1
2
3
4
Proceed with job inside unit.
Reinstall wrapper when finished.
5
Tools Needed:
3/8 in
Ref. ST-801 826-A
OM-184 227 Page 14
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5-8. Diagnostic LED’s
1
Diagnostic LED’s
1
Use diagnostic LED’s to determine
operating condition of power
source.
2
Current Source
Limit: 110 A
Fault: 115 A
3
Over Frequency
Limit: 50 kHz
Fault: 55 kHz
4
Under Frequency
Limit: 10 kHz
Fault: 5 kHz
5
Current
Reactive Limit: 700 A
Tank Voltage
6
Limit: 670 V
Fault: 1100 V Peak
7
Line Voltage
Fault: 20 %
Contactor
Lights when contactor is energized.
Over Temp
8
9
Lights when contactor is energized
and over temperature condition is
present. Also indicates top cover is
removed from unit.
FAULT
LIMIT
2
CURRENT
SOURCE
10 Tank Current
Fault Value Preset At Factory
11 Ground Fault
3
4
OVER
Lights when the ground fault
circuitry detects a short in the
output circuit between the
workpiece and power source, or
when test switch is pressed to test
ground fault circuitry.
FREQUENCY
UNDER
10
5
12 Load
Lights when no load or insufficient
load is present to couple with the
coil or blanket.
CURRENT
6
9
TANK VOLTAGE
7
LINE VOLTAGE
OVERTEMP
12
11
8
LOAD
GROUND FAULT
CONTACTOR
Ref. ST-801 826-B
OM-184 227 Page 15
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5-9. Troubleshooting
Trouble
Remedy
Replace building line fuse or reset circuit breaker.
No heat output.
Check and replace Power switch if necessary.
Connect power source to proper input voltage or check for low line voltage.
No heat output; fan motor continues to run. Safety interlock switch open. Reinstall wrapper (see Section 5-4).
Thermostat(s)TP1, TP2, and/or TP3 open (overheating). Allow fan to run; the thermostat(s) will close
Low heat output.
Check tuning of induction heating output system.
Current Source Fault LED (red) on.
Turn power off and back on again to power source one time. If fault does not clear, contact authorized
Factory Service Agent.
Over Frequency Fault LED (red) on.
Under Frequency Fault LED (red) on.
Current Fault LED (red) on.
Check for shorted coil or blanket.
Check for open circuit coil or blanket.
Check for shorted turn(s) in coil or blanket.
Check for unloaded (empty) coil.
Check for arcing between turns.
Check input line voltage.
Tank Voltage Fault LED (red) on.
Line Voltage Fault LED (red) on.
Ground Fault LED (red) on.
Check for output path to ground.
Check for human path to ground.
Check for loose coupling between coil or blanket and workpiece or pipe.
Check door switch.
Load Fault LED (red) on.
Over Temperature Fault LED (yellow) on.
Check for fan operation.
Clean unit.
Current Source Limit LED (yellow) on.
Over Frequency Limit LED (yellow) on.
Check coupling between coil and load.
Check for correct tank capacitance.
Check for shorted turns.
Under Frequency Limit LED (yellow) on.
Current Limit LED (yellow) on.
Check for correct tank capacitance.
Check tank capacitance.
Tank Voltage LED (yellow) on.
5-10. Tuning Chart
Y
Energizing contactor without at least 1 tuning capacitor in output circuit will damage power
source.
DO NOT operate power source without at least 1 tuning capacitor in output circuit.
Voltage*
High
Current (Amperage)*
Frequency (KHz)
Corrective Action
Lower inductance or decrease matching transformer turns ratio
Add capacitance
Low
Low
Low
High
High
Low
High
High
High
Mid-Range
Low
Decrease matching transformer turns ratio and add capacitance
Lower capacitance
Low
Low
High
Increase matching transformer turns ratio, or lower capacitance and
increase inductance
Low
High
Mid-Range
Increase matching transformer turns ratio and lower capacitance
*High voltage > 650 V rms; Low voltage < 450 V rms; Operating current range: 0 to 750 A rms
The power source is factory set for 4.5 mfd, but is capable of being set for 6 mfd. If a certain application requires the higher capacitance setting, remove
insulator from front capacitor and connect with supplied hardware.
OM-184 227 Page 16
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Notes
OM-184 227 Page 17
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204 963-A
OM-184 227 Page 19
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SECTION 7 − PARTS LIST
. Hardware is common and
not available unless listed.
3
Fig. 7-2
1
35
8
31
4
36
32
30
42
41
34
9
7
5
37
6
33
10
40
39
11
18
12
13
14
15
19
20
21
38
29
16
28
17
27
25
26
24 23
22
801 828-F
Figure 7-1. Main Assembly
OM-184 227 Page 20
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 179 245 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . Figure 7-2 . . CENTER BAFFLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +179 246 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 147 876 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . 195 830 . . COVER, fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . W1 . . . . . 124 886 . . CONTACTOR, def purpose 60A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . CR1 . . . . . 000 174 . . RELAY, encl 24VAC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 179 231 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . S3 . . . . . . 011 628 . . SWITCH, lim 15A 125/250VAC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 184 698 . . CABLE, pwr 12ft 8ga 4/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 186 441 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 178 563 . . NUT, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 145 743 . . LUG, univ w/scr 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 179 235 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . F1-3 . . . . . *184 700 . . FUSE, semiconductor 50A 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 184 696 . . BLOCK, fuse semiconductor modular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 17 . . . . . . . . . . . . . 184 701 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . FM2 . . . . . 184 702 . . MOTOR, fan 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG26 . . . 135 635 . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 184 845 . . BRACKET, fan mtg small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . R1 . . . . . 073 562 . . POTENTIOMETER, cp std slot 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . RC14 . . . . 143 976 . . RCPT W/SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 199 543 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . S1 . . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . S2 . . . . . 120 376 . . SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 135 299 . . LOCK, shaft pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 171 007 . . KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . S4 . . . . . 199 672 . . SWITCH, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 194 022 . . BOOT, switch rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . PC6 . . . . . 196 854 . . CIRCUIT CARD ASSY, ground fault control . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 115 443 . . STAND-OFF, no 6-32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . . . . . . . . 106 702 . . NUT, 006-32 .31 hex .20h stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . . . . . 127 837 . . RECEPTACLE, tw lk insul fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 197 900 . . CABLE, work ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 198 035 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 197 931 . . MAGNET, permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 127 836 . . PLUG, tw lk insul male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 39 . . . PC5 . . . . . 199 533 . . CIRCUIT CARD, diagnostic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 159 035 . . CLIP, retainer lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 41 . . . . . . . . . . . . . 199 165 . . COVER, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 110 386 . . RELAY, encl 24VAC DPDT 5A/120VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-184 227 Page 21
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . PM1,2 . . . . 223 949 . . KIT, transistor IGBT module 75A 1200V 94 X 35.6MM . . . . . . . . . . . . . . . 2
. . . . . . PLG21,22 . . . 115 094 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . TP1-3 . . . . 006 334 . . THERMOSTAT,NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . SR1 . . . . . 223 950 . . KIT, diode power module/scr 75A 1600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . PC3 . . . . . 181 170 . . CIRCUIT CARD, current source interconnecting . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG23 . . . 131 204 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . F4,5 . . . . . *012 658 . . FUSE, mintr gl slo-blo 2A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 098 376 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . CT1 . . . . . 184 840 . . TRANSFORMER, current primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG13 . . . 135 635 . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 155 748 . . BUS BAR, lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . PC1 . . . . . 229 245 . . CIRCUIT CARD, current source control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG11,15 . . . 115 091 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG12 . . . . 115 092 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG14 . . . 131 204 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG16 . . . 131 056 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG17 . . . 130 203 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22
20
19
18
17
. Hardware is common and
16
not available unless listed.
15
21
14
13
12
23
7
8
11
9
10
6
5
44
4
43
24
3
2
1
25
26
38
2
27
40
37
42
36
28
29
35
2
30
31
32
39
41
34
33
30
31
801 832-C
Figure 7-2. Center Baffle Assembly
OM-184 227 Page 22
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Center Baffle Assembly (Fig 6-1 Item 2)(Continued)
. . . 9 . . . . . . . . . . . . . 179 233 . . WINDTUNNEL LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . L1 . . . . . . 180 114 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . L2 . . . . . 182 563 . . INDUCTOR, series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . CT2 . . . . . 184 842 . . TRANSFORMER, current bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . CT3 . . . . . 184 841 . . TRANSFORMER, current power feedback . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PC4 . . . . . 181 175 . . CIRCUIT CARD, bridge interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . C5-6 . . . . 179 220 . . CAPACITOR, polyp met film 1.5uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . . . 179 239 . . BUS BAR, laminated output LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 186 523 . . STRIP, mtg output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . 192 515 . . BRACKET, mtg output block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . CT4 . . . . . 185 935 . . SENSOR, tank current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 196 245 . . ENCLOSURE, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 196 247 . . TOPPLATE, output enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 196 246 . . ENDPLATE, output enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 179 238 . . BUS BAR, laminated output RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +179 236 . . MIDPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 126 026 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . Z1 . . . . . . 180 115 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 179 234 . . WINDTUNNEL RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . PC2 . . . . . 205 627 . . CIRCUIT CARD ASSY w/PLUG (service kit) bridge control . . . . . . . . . . . 1
. . . . . . . . PLG1 . . . . 131 052 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . . . . 130 203 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3 . . . . . 115 091 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4 . . . . 131 056 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG5 . . . . 131 204 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . . . . 115 092 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG7 . . . . . 115 093 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG28 . . . 131 054 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG29 . . . . 115 094 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . 179 875 . . BUS BAR, diode RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . 179 876 . . BUS BAR, diode LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . C8,10 . . . . 170 867 . . CAPACITOR. polyp film 1.5uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 C9R4/C11R3 180 711 . . SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . DM1,2 . . . . 223 948 . . KIT, diode ultra fast recovery 100A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . T1 . . . . . 182 564 . . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . DM3-6 . . . . 223 948 . . KIT, diode ultra fast recovery 100A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 37 . . PM3,4 . . . . 223 944 . . KIT, transistor (2 pc) IGBT module 150A 1200V . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . T2 . . . . . 179 870 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG50 . . . 131 055 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . FM1 . . . . . 229 514 . . MOTOR, fan 48VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG25 . . . 135 635 . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 179 872 . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 184 844 . . BRACKET, fan mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . C1-4 . . . . 174 980 . . CAPACITOR, elect 2700ufd 420VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . PLG8 . . . . . 115 092 . . HOUSING PLUG & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC8 . . . . . 135 409 . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG108 . . . 203 800 . . HOUSING RCPT & SKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC108 . . . 203 799 . . HOUSING RCPT & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . C7 . . . . . 197 276 . . CAPACITOR, polyp met film 3.00uf 700VAC . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 199 234 . . INSULATOR, tank cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 200 286 . . SCREW, 250-20 x 0.50 hex hd nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-184 227 Page 23
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Notes
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Notes
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Notes
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Effective January 1, 2006
(Equipment with a serial number preface of “LG” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2006−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2006 Miller Electric Mfg. Co.2006−01
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