OM-222 166A

June 2005

Processes

Induction Heating

Description

Induction Heating Power Source

ProHeat 35

File: Induction Heating

Visit our website at

www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION . . . . . . . . . . . . . . . . . . . 4
2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien . . . . . . . . . . . . . . . . . . . 5
2-2. Informations concernant les champs électro-magnétiques (Information EMF) . . . . . . . . . . . . . . . . . . . 6
2-3. PRINCIPALES NORMES DE SÉCURITÉ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-4. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-5. Temperature Recorder Receptacle RC9 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-6. Temperature Recorder Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-7. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-8. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 4 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3. Power Source/System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4-1. Temperature-Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4-1-1. Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4-1-2. Bake-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-4-1-3. PWHT (Post-Weld Heat Treat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4-1-4. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-4-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5. Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5-1. Temperature Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5-1-2. Custom Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6. Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-7. Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-8. Real-Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-9. System Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
 TABLE OF CONTENTS

SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-5. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 − DIAGNOSTICS & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-1. Operator Interface Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-2. Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-3. Limit Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-4. Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-5. Fault Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-6. System Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-7. Removing Wrapper and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WARRANTY
 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.
. Means “Note”; not safety related. Consult symbols and related instructions below for necessary actions
to avoid the hazards.

1-2. Induction Heating Hazards

Y The symbols shown below are used throughout this manual to D Frequently inspect input power cord for damage or bare wiring − re-
call attention to and identify possible hazards. When you see place cord immediately if damaged − bare wiring can kill.
the symbol, watch out, and follow the related instructions to D Turn off all equipment when not in use.
avoid the hazard. The safety information given below is only a
summary of the more complete safety information found in the D Do not use worn, damaged, undersized, or poorly spliced cables.
Safety Standards listed in Section 1-5. Read and follow all Safe- D Do not drape cables over your body.
ty Standards.
D Do not touch power circuit if you are in contact with the work, ground,
Y Only qualified persons should install, operate, maintain, and or another power circuit from a different machine.
repair this unit. D Use only well-maintained equipment. Repair or replace damaged
Y During operation, keep everybody, especially children, away. parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
ELECTRIC SHOCK can kill. D Keep all panels and covers securely in place.

SIGNIFICANT DC VOLTAGE exists in inverter-type

Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus power sources after removal of input power.
bars or connections are electrically live whenever D Turn Off inverter, disconnect input power, and discharge input
the output is on. The input power circuit and machine capacitors according to instructions in Maintenance Section before
internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard. touching any internal parts.

D Do not touch live electrical parts. FUMES AND GASES can be hazardous.
D Enclose any connecting bus bars and coolant fittings to prevent
unintentional contact. Induction Heating of certain materials, adhesives,
D Wear dry, hole-free insulating gloves and body protection. and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Insulate yourself from work and ground using dry insulating mats or health.
covers big enough to prevent any physical contact with the work or
ground. D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation to re-
D Additional safety precautions are required when any of the follow-
move fumes and gases.
ing electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors, D If ventilation is poor, wear an approved air-supplied respirator.
gratings, or scaffolds; when in cramped positions such as sitting, D Read and understand the Material Safety Data Sheets (MSDSs)
kneeling, or lying; or when there is a high risk of unavoidable or ac- and the manufacturer’s instruction for adhesives, fluxes, metals,
cidental contact with the workpiece or ground. For these consumables, coatings, cleaners, and degreasers.
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not D Work in a confined space only if it is well ventilated, or while wearing
work alone! an air-supplied respirator. Always have a trained watchperson near-
D Disconnect input power before installing or servicing this equip- by. Fumes and gases from heating can displace air and lower the
ment. Lockout/tagout input power according to OSHA 29 CFR oxygen level causing injury or death. Be sure the breathing air is
1910.147 (see Safety Standards). safe.
D Use only nonconductive coolant hoses with a minimum length of 18 D Do not heat in locations near degreasing, cleaning, or spraying oper-
inches (457 mm) to provide isolation. ations. The heat can react with vapors to form highly toxic and
irritating gases.
D Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes. D Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
D Always verify the supply ground − check and be sure that input pow- heated area, the area is well ventilated, and while wearing an air-
er cord ground wire is properly connected to ground terminal in supplied respirator. The coatings and any metals containing these
disconnect box or that cord plug is connected to a properly grounded
elements can give off toxic fumes if overheated. See coating MSDS
receptacle outlet. for temperature information.
D When making input connections, attach proper grounding
conductor first − double-check connections.

OM-222 166 Page 1

 FIRE OR EXPLOSION hazard. INDUCTION HEATING can cause burns.
D Do not overheat parts and adhesive. D Hot parts and equipment can injure.
D Watch for fire; keep extinguisher nearby. D Do not touch or handle induction head/coil
D Keep flammables away from work area. during operation.
D Do not locate unit on, over, or near combustible surfaces. D Do not touch hot parts bare-handed.
D Do not install unit near flammables. D Allow cooling period before handling parts or equipment.
D Do not operate unit in explosive atmosphere. D Keep metal jewelry and other metal personal items away from
head/coil during operation.

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

FALLING UNIT can cause injury. STATIC (ESD) can damage PC boards.
D Use handle and have person of adequate D Put on grounded wrist strap BEFORE handling
physical strength lift unit. boards or parts.
D Move unit with hand cart or similar device. D Use proper static-proof bags and boxes to
D For units without a handle, use equipment of store, move, or ship PC boards.
adequate capacity to lift unit.
D When using lift forks to move unit, be sure forks are long enough H.F. RADIATION can cause interference.
to extend beyond opposite side of unit.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
FLYING METAL OR ADHESIVE can injure eyes.
communications equipment.
D Wear approved safety glasses with side D Have only qualified person familiar with electronic equipment per-
shields or wear face shield. form this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
MOVING PARTS can cause injury. D If notified by the FCC about interference, stop using the equip-
ment at once.
D Keep away from moving parts such as fans. D Have the installation regularly checked and maintained.
D Keep all doors, panels, covers, and guards D Keep high-frequency source doors and panels tightly shut.
closed and securely in place.

MAGNETIC FIELDS can affect pacemakers. READ INSTRUCTIONS.

D Pacemaker wearers keep away. D Read Owner’s Manual before using or servic-
D Wearers should consult their doctor before ing unit.
going near induction heating operations. D Use only genuine Miller/Hobart replacement
parts.
OVERUSE can cause OVERHEATING
D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead
For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Y Diesel engine exhaust and some of its constituents are known
reproductive harm. Wash hands after handling. 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, Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
from Global Engineering Documents (phone: 1-877-413-5184, website: Standards Association, Standards Sales, 178 Rexdale Boulevard,Rex-
www.global.ihs.com). dale, Ontario, Canada M9W 1R3.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent Practice For Occupational And Educational Eye And Face Protection,
of Documents, U.S. Government Printing Office, Washington, D.C. ANSI Standard Z87.1, from American National Standards Institute, 11
20402. West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
National Electrical Code, NFPA Standard 70, from National Fire Protec- website: www.ansi.org).
tion Association, Batterymarch Park, Quincy, MA 02269.

OM-222 166 Page 2

1-6. EMF Information
Considerations About Induction Heating And The Effects Of Low Fre- us to draw definite conclusions about questions of possible risk or to of-
quency Electric And Magnetic Fields fer clear science-based advice on strategies to minimize or avoid
The following is a quotation from the General Conclusions Section of the potential risks.”
U.S. Congress, Office of Technology Assessment, Biological Effects of To reduce magnetic fields in the workplace, use the following proce-
Power Frequency Electric & Magnetic Fields − Background Paper, OTA- dures:
BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1. Arrange output cable to one side and away from the operator.
1989): “. . . there is now a very large volume of scientific findings based 2. Do not coil or drape output cable around the body.
on experiments at the cellular level and from studies with animals and 3. Keep power source and cable as far away from the operator as
people which clearly establish that low frequency magnetic fields can in- practical.
teract with, and produce changes in, biological systems. While most of About Pacemakers:
this work is of very high quality, the results are complex. Current scientif- Pacemaker wearers consult your doctor before welding or going near
ic understanding does not yet allow us to interpret the evidence in a welding or induction heating operations. If cleared by your doctor, then
single coherent framework. Even more frustrating, it does not yet allow following the above procedures is recommended.

OM-222 166 Page 3

 SECTION 2 − MESURES DE SECURITE POUR LE
CHAUFFAGE PAR INDUCTION
ihom_fre 8/03

AVERTISSEMENT LE CHAUFFAGE PAR INDUCTION peut être dangereux.

PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE
MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS D’UN STIMULATEUR CARDIAQUE DOIVENT
PREALABLEMENT CONSULTER LEUR MEDECIN.
Pendant les opérations de chauffage, comme dans la plupart des activités, l’opérateur s’expose à certains dangers.
Le chauffage n’est pas dangereux à condition de prendre certaines mesures. Les consignes de sécurité indiquées
ci-après ne sont qu’un résumé des informations plus détaillées se trouvant dans les normes de sécurité énumérées
à la page suivante. Lire et respecter toutes les normes de sécurité.
LES OPERATIONS D’INSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT
ETRE CONFIEES QU’A DU PERSONNEL QUALIFIE.
Danger de mort PAR ELECTROCUTION. 7. Installer et mettre cet équipement correctement à la terre
conformément au manuel utilisateur et aux codes nationaux,
Le contact de composants électriques peut gouvernementaux et locaux.
provoquer des accidents mortels ou des brûlures 8. Vérifier souvent la terre de l’alimentation − contrôler et s’assurer
graves. Le circuit de puissance et les connexions de que le conducteur de terre du câble d’alimentation est
sortie sont sous tension lorsqu’on active la sortie. Le
circuit d’alimentation et les circuits internes de la correctement relié à la borne de terre dans le boîtier de
machine sont également sous tension lorsque déconnexion ou que le connecteur est branché à une sortie de
l’alimentation est sur marche. Des équipements boîtier correctement mise à la terre.
installés ou reliés à la borne de terre de manière 9. En réalisant des connexions d’entrée brancher d’abord le
incorrecte sont dangereux. 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
2. Envelopper les connexions et raccords de refroidissement pour des fils − remplacer le câble immédiatement s’il est endommagé −
éviter tout contact accidentel. des fils dénudés peuvent provoquer des accidents mortels.
11. Arrêter tous les équipements lorsqu’ils ne sont pas utilisés.
3. Porter des gants d’isolation secs, sans trous, et une protection
12. Ne pas utiliser des câbles usés, endommagés, sous
corporelle.
dimensionnés ou mal épissés.
4. Isolez-vous de la pièce et du sol avec des tapis ou des 13. Ne pas porter les câbles autour de votre corps.
couvertures d’isolation suffisamment grands pour prévenir tout 14. Ne pas toucher le circuit électrique si vous êtes en contact avec la
contact physique avec la pièce ou la terre. pièce, la terre ou le circuit électrique d’une autre machine.
5. Déconnecter l’alimentation avant d’installer l’appareil ou d’en 15. Utiliser seulement des équipements bien entretenus. Réparer ou
effectuer l’entretien. Verrouiller ou étiqueter la sortie remplacer immédiatement des composants endommagés.
d’alimentation selon la norme OSHA 29 CFR 1910.147 Effectuer des travaux d’entretien sur l’appareil selon le manuel.
(se reporter aux Principales normes de sécurité). 16. Porter un harnais de sécurité pour effectuer des travaux
6. Utiliser seulement des tuyaux non conducteurs avec une au-dessus du sol.
longueur minimale de 460 mm pour assurer l’isolement. 17. Maintenir solidement en place tous les panneaux et couvercles.

LE CHAUFFAGE PAR INDUCTION peut 1. Ne pas toucher ou manipuler la tête/l’enroulement à induction

provoquer des blessures ou des pendant le fonctionnement.
brûlures au contact de PIECES 2. Tenir les bijoux et autres objets personnels en métal éloignés de
la tête/de l’enroulement pendant le fonctionnement.
CHAUDES OU DE L’EQUIPEMENT. 3. Laisser refroidir les composants ou équipements avant de les
manipuler.

LE CHAUFFAGE PAR INDUCTION peut La mise en place de l’appareil sur, au-dessus ou à

provoquer un incendie. proximité de surfaces inflammables peut être source
1. Ne pas surchauffer les composants ni les d’INCENDIES OU d’EXPLOSION.
adhésifs. 1. Ne pas placer l’appareil sur, au-dessus ou à proximité de
2. Attention aux risques d’incendie: tenir un surfaces infllammables.
extincteur à proximité. 2. Ne pas installer l’appareil à proximité de produits inflammables
3. Stocker des produits inflammables hors de la 3. Ne pas faire fonctionner l’appareil en atmosphère explosive.
zone de travail.

OM-222 166 Page 4

 DES FUMEES ET DES GAZ peuvent 5. Travailler dans un espace fermé seulement s’il est bien ventilé ou
être dangereux pour votre santé. en portant un respirateur. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz
Le chauffage à induction génère des fumées et des provenant du chauffage peuvent déplacer l’air, abaisser le niveau
gaz. Leur inhalation peut être dangereuse pour votre d’oxygène, et provoquer des lésions ou des accidents mortels.
santé. S’assurer que l’air ambiant ne présente aucun danger.
6. Ne pas chauffer dans des endroits se trouvant à proximité
1. Eloigner la tête des fumées. Ne pas respirer les fumées. d’opérations de dégraissage, de nettoyage ou de pulvérisation. La
2. A l’interieur, ventiler la zone et/ou utiliser un extracteur pour chaleur peut réagir en présence de vapeurs et former des gaz
l’évacuation des fumées et des gaz. hautement toxiques et irritants.
3. Si la ventilation est insuffisante, utiliser un respirateur à 7. Ne pas chauffer des métaux munis d’un revêtement tels que l’acier
alimentation d’air homologué. galvanisé, plaqué au plomb ou au cadmium, à moins que le
4. Lire les spécifications de sécurité des matériaux (MSDSs) et les revêtement ne soit enlevé de la zone chauffée, que la zone soit
instructions du fabricant concernant les adhésifs, les métaux, les bien ventilée et, si nécessaire, en portant un respirateur. Les
consommables, les revêtements, les nettoyants et les revêtements et tous les métaux contenant ces éléments peuvent
dégraisseurs. 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 UNE UTILISATION INTENSIVE peut provo-
des blessures personnelles graves et en- quer un SURCHAUFFEMENT DU MATERIEL.
dommager les équipements. 1. Prévoir une période de refroidissement
1. Utiliser la poignée et demander à une personne 2. Réduire le courant de sortie ou le facteur de marche
ayant la force physique nécessaire pour soulever avant de recommencer le chauffage.
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-
3. Pour les appareils sans poignée utiliser un équipe-
ger les composants des tableaux électri-
ment d’une capacité appropriée pour soulever ques.
l’appareil. 1. Etablir la connexion avec la barrette de terre avant
de manipuler des cartes ou des pièces.
4. En utilisant des fourches de levage pour déplacer 2. Utiliser des pochettes et des boîtes antistatiques
l’unité, s’assurer que les fourches sont suffisamment pour stocker, déplacer ou expédier des cartes PC.
longues pour dépasser du côté opposé de l’appareil.

Il subsiste DU COURANT CONTINU IMPOR-

LA PROJECTION DE PIECES DE METAL ou TANT après la mise hors tension de l’alimen-
DE COLLE peut provoquer des blessures tation électrique.
aux yeux. 1. Avant de toucher des organes internes, arrêter la
source électrique, débrancher l’alimentation, et dé-
1. Porter des lunettes de protection avec des protec-
charger les condensateurs d’alimentation conformé-
tions latérales.
ment aux instructions indiquées dans la partie main-
tenance.
DES ORGANES MOBILES peuvent LE RAYONNEMENT HAUTE FREQUENCE
provoquer des blessures. peut provoquer des interférences avec les
équipements de radio-navigation et de com-
1. S’abstenir de toucher des organes mobiles tels que
des ventilateurs. munication, les services de sécurité et les or-
dinateurs.
2. Maintenir fermés et fixement en place les portes, pan- • Demander seulement à des personnes qualifiées
neaux, recouvrements et dispositifs de protection. familiarisées avec des équipements électroniques
de faire fonctionner l’installation.
• L’utilisateur est tenu de faire corriger rapidement par
un électricien qualifié les interférences résultant de
l’installation.
DES CHAMPS MAGNETIQUES CREES PAR
DES COURANTS ELEVES peuvent affecter le • Si le FCC signale des interférences, arrêter immé-
fonctionnement du stimulateur cardiaque. 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- • Maintenir soigneusement fermés les portes et les
bord consulter leur médecin avant de s’approcher panneaux des sources de haute fréquence.
des opérations de chauffage à induction.

OM-222 166 Page 5

2-2. Informations concernant les champs électro-magnétiques (Information EMF)
Considérations relatives au chauffage à induction et aux effets des proposer des recommandations scientifiques claires pour des
champs électriques et magnétiques basse fréquence. stratégies à suivre en vue de minimiser ou de prévenir des risques
Le texte suivant est extrait des conclusions générales Département potentiels.”
du Congrès U.S., Office of Technology Assessment, Effets Pour réduire les champs magnétiques sur le poste de travail,
biologiques des champs magnétiques et électriques basse appliquer les procédures suivantes :
fréquence − Background Paper, OTA-BP-E-53 (Washington, DC:
U.S. Government Printing Office, May 1989): “. . . on dispose 4. Disposer le câble de sortie d’un côté à distance de l’opérateur
maintenant d’importantes découvertes scientifiques reposant sur
des expériences effectuées dans le domaine cellulaire et des études 5. Ne pas enrouler ou draper le câble électrique autour du corps.
réalisées sur des animaux et des personnes qui démontrent
clairement que des champs magnétiques basse fréquence peuvent 6. Placer la source de courant et le câble le plus loin possible de
avoir une interaction et produire des changements dans les l’opérateur.
systèmes biologiques. Alors que la plus grande partie de cet ouvrage
est d’une très grande qualité, les résultats sont complexes. La En ce qui concerne les stimulateurs cardiaques
compréhension scientifique courante ne nous permet pas encore
d’interpréter la preuve fournie dans un seul ouvrage cohérent. Il est Les procédures ci-dessus concernent également les porteurs de
encore plus frustrant de ne pas pouvoir tirer des conclusions stimulateur cardiaque. Consulter votre médecin pour un complément
définitives en ce qui concerne les problèmes de risque possible ou de d’information.

2-3. PRINCIPALES NORMES DE SÉCURITÉ

Normes de sécurité et de santé, OSHA 29 CFR 1910, from Code électrique du Canada, partie 1, CSA Standard C22.1, from
Superintendent of Documents, U.S. Government Printing Office, Canadian Standards Association, Standards Sales, 178 Rexdale
Washington, D.C. 20402. Boulevard,Rexdale, Ontario, Canada M9W 1R3.
Code électrique national, NFPA Standard 70, from National Fire Safe Practices For Occupation And Educational Eye And Face
Protection Association, Batterymarch Park, Quincy, MA 02269. Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.

OM-222 166 Page 6

 SECTION 3 − INSTALLATION
3-1. Specifications

Amperes Input at
Required Rated Load Output
Output Rated Output
Reflective 50 or 60 Hz, Overall Dimensions Weight
Frequency Three-Phase
Inductance
Single Output Dual Output 460 V 575 V kVA kW
Length: 36-3/4 in
35 kW At 35 kW At
(993 mm)
100% Duty 100% Duty
Width: 21-1/2 in 227 lb
5 To 30 kHz Cycle Cycle 2.5 To 50 μh 58 A 40 A 39 37
(546 mm) (103 kg)
350 A (RMS), 500 A (RMS),
Height: 29 in
700 V (RMS) 700 V (RMS)
(737 mm)
*While idling

WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,
computers, and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut.

OM-222 166 Page 7

 3-2. Power Source Output Connections
2 1

Dual Air-Cooled
Output Connection
2 1

2 1

4 4

Dual Liquid-Cooled
Output Connection

2 1

Single Air-Cooled Single Liquid-Cooled

Output Connection Output Connection 5 5

2 1 2 1

5
4
3 3

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

1. Output Connector 1 connections. Dual Air-Cooled Output Connection

2. Output Connector 2 Single Air-Cooled Output Connection Connect air-cooled output extension
3. Protective Plug Connect air-cooled output extension cable cables to Output Connector 1 and Output
to Output Connector 1 or Output Connector 2.
4. Air-Cooled Extension Cable
Connector 2. Connect Protective Plug to Dual Liquid-Cooled Output Connection
5. Liquid-Cooled Extension Cable
remaining Output Connector.
The power source is capable of single or Connect liquid-cooled output extension
Single Liquid-Cooled Output Connection cables to Output Connector 1 and Output
dual output. When connected for single
power output, up to 35 kW is available at Connect liquid-cooled output extension Connector 2.
the single output connection. When cable to Output Connector 1 or Output
connected for dual power, output power is Connector 2. Connect Protective Plug to . Extension cables must be the same
divided between the two output remaining Output Connector. length: 25 ft (7.6 m) or 50 ft (15.2 m).

OM-222 166 Page 8

3-3. Remote 14 Receptacle RC14 Information and Connections
1. Plug
2. Threaded Collar
3. Keyway
4. Remote 14 Receptacle RC14
3 (See Section 3-4)
To connect to receptacle, align key-
way, insert plug and tighten
threaded collar.
A J 4
K I
B
2 1 C L N H
D M G
E F

803 992-A

3-4. Remote 14 Socket Information

Socket Socket Information

A +24 volts dc.

Remote Contactor
B Contact closure to A completes 24 volts dc contactor control circuit.

C Command reference; +10 volts dc.

D Control circuit common.
Remote Output Control
E Input command signal (potentiometer wiper or 0 to +10 volts dc).
G Not used.
Absence of internal contact closure between F and J signals power source error to remote
F, J Power Source Limit
control device.

H Current No. 2 output

p signal
g RMS ((1 volt/100 amperes).
p )
I Actual frequency output signal (1 volt/10 kHz).
L Average power output signal (1 volt/5 kW).
Remote Metering
M Voltage output signal RMS (1 volt/100 volts).
N Total current output signal RMS (1 volt/100 amperes).
K Ch
Chassis
i common.

OM-222 166 Page 9

 3-5. Temperature Recorder Receptacle RC9 Information And Connections
1. Plug
2. Threaded Collar
3. Temperature Recorder
Receptacle RC9 (See Section
3-6)
To connect to receptacle, insert
3
plug and tighten threaded collar.

2 1

803 992-A

3-6. Temperature Recorder Socket Information

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

OM-222 166 Page 10

3-7. Secondary Insulation Protection
Secondary insulation protection
circuitry automatically shuts down
the power source output if a
potentially hazardous condition
exists at the heating device
connected to the power source (e.g.
insulation has broken down on a
heating blanket causing the
conductor to come into contact with
the workpiece or a heating coil
touches the workpiece causing a
short in the output circuit).
The supplied ground lead(s) must
be connected between the
workpiece and power source to
provide proper secondary insula-
tion protection from a short in the
output circuit.
For single output, only one
ground lead is required. For dual
output , use both ground leads.
1. Receptacles
2. Plug
To connect plug, align key with key-
way, insert end into receptacle, and
rotate plug until tight.
3. Handle
4. Magnet
5. Workpiece
Use handle to place magnet on the
workpiece.

1
2

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

OM-222 166 Page 11

 3-8. 115 Volt AC Duplex Receptacle And Supplementary Protector
1. 115 VAC 2.5 A Single-Phase
AC Receptacle RC2
2. Supplementary Protector CB1
(2.5 A)
The receptacle supplies nominal 115
volts ac auxiliary power for use with
the optional digital recorder. Maxi-
mum output from receptacle is 2.5
amperes.
1 CB1 protects 115 volt receptacle
RC2 from overload. If CB1 opens,
RC2 does not work.
2 1

803 993-B

3-9. Electrical Service Guide

60 Hz Three Phase
Input Voltage 460 575
Input Amperes At Rated Output 58 40
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 1
Circuit Breaker 1, Time-Delay 2 61 45
Normal Operating 3 70 60
Min Input Conductor Size In AWG 4 8 8
214 334
Max Recommended Input Conductor Length In Feet (Meters)
(65) (102)
Min Grounding Conductor Size In AWG 4 8 10

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

OM-222 166 Page 12

3-10. Connecting Input Power
Tools Needed:
3/8 in

8
2

L1
L2 5
6 L3
3

12 9 13 10 11
Ref. 803 99-B

Y Installation must meet all National and Select size and length using Section 3-9. 8. Primary Cover
Local Codes − have only qualified per- Conductor rating must comply with national,
Open primary cover.
sons make this installation. state, and local electrical codes.
2. Disconnect Device Of Proper Rating 9. Input Conductors
Y Disconnect and lockout/tagout input
power before connecting input con- (Switch Shown In The Off Position) 10. Grounding Conductor
ductors from unit. 3. Green Or Green/Yellow Grounding 11. Strain Relief Connector
Conductor
Y Always connect green or green/yellow Route input power cord through strain relief on
conductor to supply grounding termi- 4. Disconnect Device Grounding Terminal rear panel to fuse block.
nal first, and never to a line terminal. 5. Input Conductors (L1, L2 And L3) 12. Input Junction Block
6. Disconnect Device Line Terminals
. The circuitry in this unit automatically
Connect green or green/yellow grounding
13. Power Source Ground Terminal
adapts the power source to the primary Connect grounding conductor to ground
voltage being applied. Check input conductor to disconnect device grounding
terminal first. Then connect input conductors
voltage available at site. This unit can be terminal first.
to junction block.
connected to either 460 or 575 VAC input Connect input conductors L1, L2 and L3 to
power. disconnect device line terminals. Reinstall fuse block cover.
7. Over-Current Protection Tighten strain relief. Close and secure primary
1. Input Power Cord
cover.
Select type and size of over-current protection
. If using individual grounding and input using Section 3-9. Install into deenergized line Close and secure door on disconnect device.
conductors, install in conduit or equivalent disconnect device (fused disconnect switch Remove lockout/tagout device, and place
to deenergized line disconnect device. shown). switch in the On position.

OM-222 166 Page 13

 SECTION 4 − COMPONENTS AND CONTROLS
4-1. Controls
3 4 5 6 7 10 9 8 11 18

16

17
2

15

14

19 13
12

803 995

. When a control panel button is pushed LED lights to indicate a system limit condi-
tion.
14. Parameter Button
the yellow lamp lights to indicate ac- Use button to display “real time” power
tivation. 7. Heat On LED source operating parameters.
1. Power Switch LED lights to indicate the power source out- 15. Cooler Button
put is energized.
Use switch to turn power source On and Use button to turn cooler On and Off.
Off. 8. Stop Button
Use button to stop a heating process. 16. Increase Button
2. TC1−4 Temperature Display
9. Hold Button Use button to increase values in set-up
Provides temperature display of thermo- screen.
couples 1 through 4. Use button to hold a heating process.
3. Control Thermocouple LED’s 10. Run Button 17. Decrease Button
LED’s indicate which thermocouples (1−4) Use button to run a heating process. Use button to decrease value in program
are used to control the heating process. 11. Cursor Button screen.
4. Temperature Units LED’s Use button to move selection cursor in the 18. 4 x 40 LCD Display
LED’s indicate units for temperature mea- 4 x 40 LCD display (item 18.). Displays programming, runs status, pa-
surements (°F or ° C). 12. Program Button rameter, fault and limit conditions, and trou-
5. Fault LED Use button to program the process control. bleshooting guide.
LED lights to indicate a system fault condi- 13. Run Status Button 19. Thermocouple Input Receptacles
tion. Use button to display “real time” operating Use receptacles for type K thermocouple
6. Limit LED status. inputs.

OM-222 166 Page 14

 SECTION 5 − SETUP AND OPERATION
5-1. Safety Equipment
Wear the following during
1 2 operation:
1. Dry, Insulating Gloves
2. Safety Glasses With Side
Shields
DO NOT wear rings or watches
during operation.
sb3.1* 1/94

5-2. System Description

The ProHeat 35 Induction Heating Power Source is designed to function either as an air-cooled system or a liquid-
cooled system. Depending on the system type (either air-cooled or liquid-cooled), the power source is automatically
configured to operate and provide an output appropriate for the type of connected heating device.
A special identifier, embedded within the extension cable connector, provides the means for the power source to con-
figure itself by recognizing the type of extension cable(s) attached to its output connectors.
Designed to provide a single level of output (up to 35 kW), the ProHeat 35 power source has two panel mounted con-
nectors that are connected in parallel to the power source output. This design allows the system to operate with either
a single output extension cable or two output extension cables.
If a single output extension cable is used, a protective plug (provided with the system) MUST be placed on the unused
output connector or the system will not operate. If two output extension cables are used, they both MUST be of the
same type (either both air-cooled or both liquid-cooled) or the system will not operate (in this case, the protective plug
is not used). When two extension cables and heating devices are utilized on the system, the extension cable lengths
and heating devices MUST be identical (see Section 3-2).
The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating
parameters or internal temperatures reach or exceed specific set limits (see Section 8).

5-3. Power Source/System Setup

kW
To view the “System Setup” screen, simultaneously press the “Parameters” V
A
Hz
and “Program” buttons

and the following screen will appear on the display:

System Setup Screen

Degree Units . : >°F SYSTEM SETUP

Tolerance. . . . . : ±25 Backlight: Yes

Input Type . . . : K TC Control Mode: Temp

Power Output : 35kW System Lock: No

To change a setting:

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

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

OM-222 166 Page 15

 Possible selections:
Degree Units: °F / °C
Tolerance: ±5 to 99 in °F (±3 to 55 in °C)
Backlight: Yes / No
Input Type: K TC
Control Mode: Temp / Time / Manual
Power Output: 1 to 35
System Lock: Yes / No

Degree Units − press the “Increase” or “Decrease” buttons to select temperature units. Selection will

drive the °F / °C indicator LED’s.

S The factory default is °F.
S Changing from °F to °C will convert stored program values: ramp temperature, soak temperature, ramp rate,
and temperature tolerance.

Tolerance − press the “Increase” or “Decrease” button to select the desired temperature tolerance.

S The factory default is ±25 °F.

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

S The factory default is On.

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

device.
S The factory default and only selection is “K TC”.

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

control, either “Temperature” or “Manual”. For more details about methods of control, see Section or .
S The factory default is temperature based control.

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

output.
S The factory default is 35 kW.

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

prevent tampering with any programs. Yes indicates the system is locked, and No indicates the
system is unlocked.
S The factory default is No (unlocked).

OM-222 166 Page 16

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

To reset the system back to factory default settings, simultaneously press and hold the “Increase” and

“Decrease” buttons, and turn on the power source.

5-4. Programming
Programming allows the operator to setup a program for a particular heating process. The selections available are
either “Temperature” control or “Manual” control.
5-4-1. Temperature-Based Control
Temperature-based control operates the system and controls the heating process based on temperature feedback
from thermocouple inputs. Thermocouples must be used for this mode of operation or the system will not operate.
Within the temperature-based mode there are four different processes available as follows: Preheat, Bakeout,
PWHT (Post-Weld Heat Treat), and Custom Program.
Press the Program button to access the programming mode. Use the cursor button to move the cursor to the desired
temperature-based process, then press the Program button again to select the process.
5-4-1-1. Preheat
The preheat process is a simple method of heating material to a desired temperature and holding that temperature
for a specific period of time. When this process is selected, the following screen will appear on the LCD display:
Preheat Screen

Mode . . . . . : Preheat

Control TC . : >1

Temperature : 400

Soak Time . : 01:00:00

The default position of the cursor is next to “Control TC”. Press the “Increase” or “Decrease” button

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

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

the “Increase” or “Decrease” button to change the value to the desired setting.

OM-222 166 Page 17

 NOTE The minimum and maximum temperature settings for preheat are 0 and 1000 F
(−18 and 538 C). The minimum and maximum soak times are 0 and 1000 hours.
When the system is utilizing air-cooled blankets, the maximum temperature
setting is 400 F (204 C). If the program setting is above 400 F (204 C), the
following screen will appear on the LCD display:

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 °F, 204 °C)

5-4-1-2. Bake-Out
The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from
bake-out if desired. When this process is selected, the following screen appears on the display:
Bake-Out Screen

Mode . . . . . : Bake-Out

Control TC . : >1

Soak Temp. : 600 Soak Time : 01:00:00

Cool Temp . : 200 Cool Rate : 600 °/Hr

The default position of the cursor is next to “Control TC”. Press the “Increase” or “Decrease” button

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

Use the “Cursor” button to move the cursor to the desired selection (Soak Temperature, Soak Time, Cool

Temperature, or Cool Rate), and press the “Increase” or “Decrease” button to change the value to

the desired setting.

OM-222 166 Page 18

NOTE The minimum and maximum soak temperature settings for bake-out are 0 and
1000 F(−18 and 538 C). The minimum and maximum soak times are 0 and 1000
hours. The minimum and maximum cool rates are 10 and 9999 /hr. When the
system is utilizing air-cooled blankets, the maximum temperature setting is 400
F(204 C). If the program setting is above 400 F (204 C), the following screen will
appear on the LCD display:

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 °F, 204 °C)

5-4-1-3. PWHT (Post-Weld Heat Treat)

The post-weld heat treat process allows the operator to program a post-weld heat treat where ramp temperature
(on increase and decrease) and ramp rates are the same. When this process is selected, the following screen
appears on the display:
PWHT Screen

Mode . . . . . : PWHT

Control TC . : >1

Ramp Temp. : 600 Ramp Rate : 600 °/Hr

Cool Temp . : 200 Soak Time : 01:00:00

The default position of the cursor is next to “Control TC”. Press the “Increase” or “Decrease” button

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

Use the “Cursor” button to move the cursor to the desired selection (Ramp Temperature, Ramp Rate, Soak

Temperature, or Soak Time), and press the “Increase” or “Decrease” button to change the value to

the desired setting.

OM-222 166 Page 19

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

Maximum Temperature Message Screen

Cannot enter Run mode

Programmed temperature settings

exceed air cooled limits

(400 °F, 204 °C)

5-4-1-4. Custom Program

In Custom Program, the operator can create a custom program with multiple steps or nonsymmetrical heat treat
programs where the heating and cooling rates and temperatures are different. When this process is selected, the
following screen appears on the display:

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

Custom Program Screen

Mode . . . . . : Custom Program

Segment . . . : >1

Type. . . . . . : End

Control TC. : 1

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

to increase or decrease the segment number, unless the segment type is “End”. In this case, the segment number
will advance to segment 1.

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

“Increase” or “Decrease” button to change the value to the desired setting. When the cursor is

moved to the “Type” selection, pressing the “Increase” or “Decrease” button changes the segment

type to “Step”, “Ramp”, “Soak”, or “End”. The functions of each segment type are as follows:
S “Step” increases the temperature in the part at full-programmed power. A maximum temperature of 1450° F
(788° C) can be programmed.

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S “Ramp” increases or decreases the temperature in the part at a controlled rate in degrees per hour. A
maximum temperature of 1450° F (788° C) and a maximum rate of 9999° F/hr (5555° C/hr) can be
programmed.
S “Soak” will hold the temperature for a programmed time. A maximum hold (soak) time of 99:59
(hours:minutes) can be programmed.
S “End” is programmed to indicate the completion of the cycle and termination of output power.
Step Function
When type is set to “Step”, the following screen appears on the display:
Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 1

Type. . . . . . . . : >Step

Temperature. . : 600

Use the “Cursor” button to move the cursor to the “Temperature” position and the initial temperature can be

adjusted using the “Increase” or “Decrease” button.

Pressing the “Cursor” button again automatically advances the program to the next segment number.

Ramp Function
When type is set to “Ramp”, the following screen appears on the display:
Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 2

Type. . . . . . . . : >Ramp

Temperature. . : 600 Ramp Rate: 600 °/Hr

Use the “Cursor” button to move the cursor to the “Temperature” or “Ramp Rate” position and use the

“Increase” or “Decrease” button to set the desired value.

When the cursor is in the “Ramp Rate” position, pressing the “Cursor” button again automatically advances

the program to the next segment number.

OM-222 166 Page 21

 Soak Function
When type is set to “Soak”, the following screen appears on the display:
Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 3

Type. . . . . . . . : >Soak

Soak Time. . . . : 01:00:00

Use the “Cursor” button to move the cursor to the “Soak Time” position and use the “Increase” or

“Decrease” button to set the desired value.

When the cursor is in the “Soak Time” position, pressing the “Cursor” button again automatically advances

the program to the next segment number.

End Function
When type is set to “End”, the following screen appears on the display:
Custom Program Screen

Mode . . . . . . . : Custom Program

Segment . . . . . : 4

Type. . . . . . . . . : >End

Control TC. . . . : 1,2,3,4

The only changeable parameter in the “End” segment is selecting the number of thermocouples. Use the “Cursor”

button to move the cursor to the “Control TC” position. Press the “Increase” or “Decrease”

button to select the number of control thermocouples to be used for the program. Selections are as follows: “1”,
“1,2”, “1,2,3”, or “1,2,3,4”. TC1 MUST always be a control thermocouple. TC2 thru TC4 can be used for controlling
or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
A custom program can contain up to 10 segments. To view Program parameters, position the cursor at segment

and use the “Increase” or “Decrease” button to advance through the segment numbers until the

“End” segment. When a segment number is changed, appropriate segment parameter information appears on the
display.

OM-222 166 Page 22

Typical 5-Segment Custom Program
Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 1

Type. . . . . . . . : >Step

Temperature. . : 600

Temperature increases to 600 degrees at full-programmed power.

Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 2

Type. . . . . . . . : >Ramp

Temperature. . : 1250 Ramp Rate: 600 °/Hr

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

Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 3

Type. . . . . . . . : >Soak

Soak Time. . . . : 01:00:00

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

Custom Program Screen

Mode . . . . . . : Custom Program

Segment . . . . : 4

Type. . . . . . . . : >Ramp

Temperature. . : 600 Ramp Rate: 600 °/Hr

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

Custom Program Screen

Mode . . . . . . . : Custom Program

Segment . . . . . : 5

Type. . . . . . . . . : >End

Control TC. . . . : 1,2,3,4

End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.
OM-222 166 Page 23
 5-4-2. Manual Control
“Manual” control allows programming of a specific power level for a specific period of time. When this process is
selected, the following screen appears on the display:
Custom Program Screen

Mode . . . : Custom Program Power. : 0.0 KW

Command. : 0.0 KW Current : 0A

Run Time : >00:00:00 Voltage : 0V

Frequency : 4.5 KHZ

The only programmable selections are “Command” power and “Run Time”. Command can be adjusted to deliver up
to 35 KW (based on maximum power selected in the set-up screen) for a period of up to 99 hours, 59 minutes.
Power source operating power, current, voltage, and frequency are shown on the right-hand side of the display.

To reset the system back to factory default settings, simultaneously press and hold the “Increase” and

“Decrease” buttons, and turn on the power source.

5-5. Run Status

Run status allows the operator to check status of a program during in-process heating. Depending on the control mode
(Temperature or Manual) and the temperature based mode (Preheat, Bake-Out, PWHT, or Custom), different style
screens appear on the display. Run status is for monitoring purposes only and has no selectable or changeable
parameters.

5-5-1. Temperature Based Control

5-5-1-1. Preheat, Bake-Out And PWHT Run Status Screen
Run Status Screen

Mode . . . . . . : Preheat TC5 : 75

Target Temp : −−−−−− TC6 : 75

Countdown : −−:−−:−−

Status. . . . . . : Stopped

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

OM-222 166 Page 24

 5-5-1-2. Custom Program
Run Status Screen

Mode . . . . . : Custom Program TC5 : 75

Target Temp : −−−−−− TC6 : 75

Countdown : −−:−−:−−

Status. . . . . . : Stopped Segment : 1

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

5-5-2. Manual Control

Run Status Screen

Mode . . . . . . : Manual TC5 : 75

Power . . . . : 0.0 KW TC6 : 75

Countdown : −−:−−:−−

Status. . . . . . : Stopped

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

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

5-6. Parameters
During active operation, the “Parameters” screen allows the operator to monitor the power source output operating
parameters. These parameters include output power, output amperage, output voltage, and output frequency. In addi-
tion, temperatures of thermocouples TC5 and TC6 are also displayed. The Parameters screen is for monitoring
purposes only and has no selectable or changeable parameters.
Parameters Screen

Power . . . : 0.0 KW TC5 : 77

Current . . : 0A TC6 : 77

Voltage . . : 0V

Frequency : 4.5 KHZ

5-7. Cooler

The “Cooler” button is used to turn the cooler On or Off (liquid-cooled systems only). On liquid-cooled systems,

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

OM-222 166 Page 25

system will automatically start the cooler when the “Run” button is pressed. Pressing the “Stop” button

does not shut off the cooler. The cooler must be shut off separately by pressing the “Cooler” button.

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

output is energized, the following screen will appear on the display:

Cooler Message Screen

Cooler cannot be turned off

while output is on.

NOTE The “Cooler” button is inactive on systems using air-cooled extension cables and
heating blankets.

5-8. Real-Time Operation

Each time the unit is first turned On it initiates a system check routine that includes verification of communication be-
tween circuit boards and checking for output isolation faults. During this check routine, all displays and LED’s
illuminate. If an error is detected during the check routine, the system fault LED illuminates and an error message
screen appears on the display (see Section 8-5).
If no errors are detected during the check routine, the following screen appears on the display:
Power Up Message Screen

ProHeat 35

Firmware Revision X.XX

Copyright (c) 2005

Miller Electric Mfg. Co.

X.XX indicates the firmware revision number installed in the unit.

When the check routine is completed successfully, the operator interface defaults to the following:

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

S The temperature displays indicate actual temperature from the TC’s (thermocouples). If no thermocouples
are connected, the display indicates “open”.
S “Control” LED’s illuminate to indicate the number of control TC’s in the last program.
S The appropriate degree units (°F or °C) light illuminates.

OM-222 166 Page 26

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

button indicator LED illuminates.

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

Once set up is complete for the desired program procedure (see Section 5-3), pressing the “Run” button will

initiate a heating cycle. When a program run is initiated, the “Run” button yellow indicator LED illuminates and

the “Heat On” blue indicator LED illuminates to indicate output is present to the coil. The cycle will continue until the end

of the program is reached or the “Stop” button is pressed.

The system has a hold function that will maintain a temperature or hold the soak time of any active temperature

controlled program. Pressing the “Hold” button will only activate the hold function while in the run mode. If the

system is not in the run mode, the following screen will appear on the display:
Hold Message Screen

Must be running to enter hold mode.

In addition, when running in “Manual” operating mode, the “Hold” button is not functional. If the system is

running in “Manual” operating mode, pressing the “Hold” button will cause the following screen to appear on

the display:
Hold Message Screen

Hold mode not available when

temperature control is not active.

Pressing the “Hold” button will activate the hold function while running a temperature controlled program.

While in the hold mode, the parameters for the program in process can be modified. The cycle will continue after press-

ing the “Run” button. A change of program parameters during the hold will not change the original program.

The original program parameters are maintained for the next heating cycle.

OM-222 166 Page 27

To make changes to a program while in run mode, press the “Hold” button and the yellow indicator LED will

illuminate, and the “Run” button yellow indicator LED will turn off. When in hold, the system will maintain the

actual temperature of the hottest thermocouple while the program is being changed.

S Press the “Program” button and the yellow indicator LED will illuminate. The display will change to

show the current mode of operation or the current segment of a Custom Program.

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

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

S Press the “Run” button to resume program operation and the yellow indicator LED will illuminate, and

the “Hold” button yellow indicator LED will turn off.

Any program parameter (temperatures, rates, times, or number of TC’s) can be changed while in hold. In a custom
based program, any segment number can be changed; however, if the operation of a segment has already been com-
pleted in a program, the change to that segment will not affect the program function.

NOTE Regardless of the program status or power source operating status, pressing the
“Stop” button will terminate output power and reset the program. In the case of
Custom Programs, the system will reset to Segment 1.

OM-222 166 Page 28

5-9. System Operating Characteristics
The power source delivers a high-frequency alternating current output that energizes the coil creating the magnetic
field used to heat the workpiece. The power source output characteristics are a function of the configuration, type and
number of coils used as shown in the following table:

Table 5-1. Power Source Output Characteristics

Output Type Maximum Amperage Maximum Voltage Frequency Range
250 A per output for 15 minutes.
After 15 minutes, power step
down to limit current to 150 am- 700 V 5 − 25.7 kHz
Air Cooled Single and Dual peres per output for continuous
operation.
See Note 1 700 V 25.7 − 30 kHz
350 A 700 V 5 − 20 kHz
Single Liquid Cooled
See Note 2 700 V 20 − 30 kHz
350 A per output/500 A total 700 V 5 − 20 kHz
Dual Liquid Cooled
See Note 2 700 V 20 − 30 kHz

Note 1: Above 25.7 kHz, the output dwells back to linearly decrease the output amperage to a maximum of 175
amperes per output at 30 kHz. In this frequency range (25.7 − 30 kHz), the system will deliver the level of current
dictated by the linear amperage decrease, and then step down to 150 amperes per output after 15 minutes.
Note 2: Above 20 kHz, the output dwells back to linearly decrease the output amperage to a maximum of 175 amperes
per output at 30 kHz. In this frequency range (20 − 30 kHz), the system will deliver the level of current dictated by the
linear amperage decrease.

OM-222 166 Page 29

 SECTION 6 − MAINTENANCE

6-1. Routine Maintenance

Y Disconnect power . Maintain more often

before maintaining. during severe conditions.

3 Months
2 1 2 1
Replace Clean Output Clean Ground
Damaged Or Connector Sense Lead
Unreadable Contacts Receptacles
Labels

Repair Or Replace
Cracked Cables
And Cords

2 1
Clean Operator Check Integrity Of
Interface Overlay Protective Plug,
Replace If Necessary

6 Months

Blow Out Or
Vacuum Inside
Of Wind Tunnel

OM-222 166 Page 30

6-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front louvers and back slots
as shown.

803 992-A

OM-222 166 Page 31

 SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING
7-1. Symbol Usage
safety_ihom 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
. Means “Note”; not safety related. Consult symbols and related instructions below for necessary actions
to avoid the hazards.

7-2. Induction Heating Hazards

Y The symbols shown below are used throughout this manual to SIGNIFICANT DC VOLTAGE exists after removal of
call attention to and identify possible hazards. When you see input power on inverters.
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only D Turn Off inverter, disconnect input power, and discharge input
a summary of the more complete safety information found in capacitors according to instructions in Maintenance Section before
the Safety Standards listed in Section 7-4. Read and follow all touching any internal parts.
Safety Standards.
Y Only qualified persons should install, operate, maintain, and INDUCTION HEATING can cause burns.
repair this unit.
Y During operation, keep everybody, especially children, away. D Hot parts and equipment can injure.
D Do not touch or handle induction head/coil
during operation.
ELECTRIC SHOCK can kill. D Do not touch hot parts bare-handed.
D Allow cooling period before handling parts or equipment.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus D Keep metal jewelry and other metal personal items away from
bars or connections are electrically live whenever head/coil during operation.
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. FIRE OR EXPLOSION hazard.
D Do not touch live electrical parts.
D Do not overheat parts and adhesive.
D Enclose any connecting bus bars and coolant fittings to prevent
D Watch for fire; keep extinguisher nearby.
unintentional contact.
D Keep flammables away from work area.
D Wear dry, hole-free insulating gloves and body protection.
D Do not locate unit on, over, or near combustible surfaces.
D Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or D Do not install unit near flammables.
ground. D Do not operate unit in explosive atmosphere.
D Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA 29 CFR FUMES AND GASES can be hazardous.
1910.147 (see Safety Standards).
D Use only nonconductive coolant hoses with a minimum length of 18
Induction Heating of certain materials, adhesives,
inches (457 mm) to provide isolation. and fluxes can produce fumes and gases. Breathing
D Properly install and ground this equipment according to its Owner’s these fumes and gases can be hazardous to your
Manual and national, state, and local codes. health.
D Always verify the supply ground − check and be sure that input pow- D Keep your head out of the fumes. Do not breathe the fumes.
er cord ground wire is properly connected to ground terminal in D If inside, ventilate the area and/or use exhaust to remove fumes
disconnect box or that cord plug is connected to a properly and gases.
grounded receptacle outlet.
D If ventilation is poor, use an approved air-supplied respirator.
D When making input connections, attach proper grounding
D Read the Material Safety Data Sheets (MSDSs) and the
conductor first − double-check connections.
manufacturer’s instruction for adhesives, fluxes, metals,
D Frequently inspect input power cord for damage or bare wiring − re- consumables, coatings, cleaners, and degreasers.
place cord immediately if damaged − bare wiring can kill.
D Work in a confined space only if it is well ventilated, or while wearing
D Turn off all equipment when not in use. an air-supplied respirator. Always have a trained watchperson
D Do not use worn, damaged, undersized, or poorly spliced cables. nearby. Fumes and gases from heating can displace air and lower
D Do not drape cables over your body. the oxygen level causing injury or death. Be sure the breathing air is
safe.
D Do not touch power circuit if you are in contact with the work,
ground, or another power circuit from a different machine. D Do not heat in locations near degreasing, cleaning, or spraying op-
erations. The heat can react with vapors to form highly toxic and
D Use only well-maintained equipment. Repair or replace damaged
irritating gases.
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level. D Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
D Keep all panels and covers securely in place. heated area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if overheated.
See coating MSDS for temperature information.

OM-222 166 Page 32

7-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING
D Use handle and have person of adequate D Allow cooling period.
physical strength lift unit. D Reduce output or reduce duty cycle before
D Move unit with hand cart or similar device. starting to heat again.
D For units without a handle, use equipment of D Follow rated duty cycle.
adequate capacity to lift unit.
D When using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of unit. STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
FLYING METAL OR ADHESIVE can injure eyes. boards or parts.
D Use proper static-proof bags and boxes to
D Wear approved safety glasses with side store, move, or ship PC boards.
shields or wear face shield.

H.F. RADIATION can cause interference.

MOVING PARTS can cause injury.
D High-frequency (H.F.) can interfere with radio
D Keep away from moving parts such as fans. navigation, safety services, computers, and
communications equipment.
D Keep all doors, panels, covers, and guards
closed and securely in place. D Have only qualified person familiar with electronic equipment per-
form this installation.
D The user is responsible for having a qualified electrician promptly
MAGNETIC FIELDS can affect pacemakers. correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
D Pacemaker wearers keep away. ment at once.
D Wearers should consult their doctor before D Have the installation regularly checked and maintained.
going near induction heating operations.
D Keep high-frequency source doors and panels tightly shut.

7-4. Principal Safety Standards

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
dent of Documents, U.S. Government Printing Office, Washington, D.C. Standards Association, Standards Sales, 178 Rexdale Boulevard,Rex-
20402. dale, Ontario, Canada M9W 1R3.
National Electrical Code, NFPA Standard 70, from National Fire Protec- Safe Practices For Occupation And Educational Eye And Face Protec-
tion Association, Batterymarch Park, Quincy, MA 02269. tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.

7-5. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
Y Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other
to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling.
other reproductive harm.

7-6. EMF Information

Considerations About Induction Heating And The Effects Of Low Fre- fer clear science-based advice on strategies to minimize or avoid
quency Electric And Magnetic Fields potential risks.”

The following is a quotation from the General Conclusions Section of the To reduce magnetic fields in the workplace, use the following proce-
U.S. Congress, Office of Technology Assessment, Biological Effects of dures:
Power Frequency Electric & Magnetic Fields − Background Paper,
7. Arrange output cable to one side and away from the operator.
OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . there is now a very large volume of scientific findings based 8. Do not coil or drape output cable around the body.
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can 9. Keep power source and cable as far away from the operator as
interact with, and produce changes in, biological systems. While most of practical.
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 About Pacemakers:
single coherent framework. Even more frustrating, it does not yet allow
us to draw definite conclusions about questions of possible risk or to of- The above procedures are also recommended for pacemaker wearers.
Consult your doctor for complete information.

OM-222 166 Page 33

 SECTION 8 − DIAGNOSTICS & TROUBLESHOOTING
The ProHeat 35 power source has on-board capabilities to aid in troubleshooting problems should any conditions
occur during operation. This troubleshooting capability consists of the Fault LED, Limit LED, and message screens
that appear on the front panel LCD display.

8-1. Operator Interface Indicators

1 2 3

803 995

1 Fault LED 2 Limit LED 3 4 x 40 LCD Display

Displays programming, run status, param-
LED lights to indicate a system fault LED lights to indicate a system limit eters, fault and limit conditions, and
condition. condition. troubleshooting guide.

OM-222 166 Page 34

8-2. Limit Conditions
A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its
optimum operating conditions or parameters. Should a limit condition occur during operation, the yellow “Limit” LED
will flash to indicate a problem. If the active screen on the LCD display is “Run Status” or “Parameters”, a message
describing the particular limit condition will appear on the display. If the active screen is “Program”, press the “Run

Status” button to display the limit condition.

In a limit condition, the power source will continue to deliver output power and protect itself from damage by reducing
the output power. This situation allows the operator time to determine the best action to correct the problem as
described by the limit message on the LCD display.
If a limit condition occurs, there are two selectable options:
S Acknowledge the limit and continue operation.
S Terminate operation to correct the problem causing the limit.

Pressing the “Decrease” button will acknowledge the limit and continue operation with the existing set up. In

the acknowledge state, the yellow “Limit” LED will stop flashing and remain on continuously. The LCD display will
kW
revert to an active screen once the “Program” button, “Run Status” button, or “Parameters” V
A
Hz

button is pressed.
If a new limit condition should occur after the first is acknowledged, the yellow “Limit” LED will start flashing to indicate a

new problem. To display the limit condition, press the “Run Status” button and the LCD display will show a

message describing the new and previous limit messages.

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

“Increase” button, and the LCD display will indicate possible solutions based on the type of limit condition.

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

setup to eliminate the limit condition, press the “Stop” button. After changes are made to the setup, press the

“Run” button to restart the process.

8-3. Limit Condition Codes

Limit Condition Additional Information
L01: Thermocouple #1 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L02: Themocouple #2 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L03: Thermocouple #3 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L04: Thermocouple #4 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L05: Thermocouple #5 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L06: Thermocouple #6 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
OM-222 166 Page 35
 Limit Condition Additional Information
L07: Output Voltage Limit Tighten blanket against pipe surface
L08: Output Voltage Limit Increase number of turns
Increase coil space
Shorten extension cable
Increase insulation width
L09: Output Current Limit Tighten blanket against pipe surface
L10: Output Current Limit Increase number of turns
Decrease coil space
Tighten cable on insulation
L11: Coolant Overtemp Limit Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
L12: Power Source Overtemp Limit Check for blocked vents
Clean wind tunnel heat sinks
L13:Cable Connection Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected

8-4. Fault Conditions

A fault condition occurs if the system encounters an isolation fault, encounters operating conditions outside operation-
al limits, or if there is a serious problem with the system. Should a fault condition occur, the output is immediately

turned off, the red “Fault” LED flashes and the “Stop” button LED flashes. If the active screen on the LCD

display is “Run Status” or “Parameters”, a message describing the particular fault condition will appear on the display.

If the active screen is “Program”, press the “Run Status” button to display the fault condition.

Pressing the “Decrease” button will acknowledge the fault and the red “Fault” LED will stop flashing and remain

on continuously. However, the “Stop” button LED will continue to flash indicating that the process has stopped.

To obtain additional information regarding the fault condition and suggested solutions to resolve the fault, press the

“Increase” button, and the LCD display will indicate possible solutions based on the type of fault condition. In

most cases, a fault condition will indicate that service is required.

8-5. Fault Condition Codes
Fault Condition Additional Information
F51: Thermocouple #1 Internal Fault Service required
F52: Themocouple #2 Internal Fault Service required
F53: Thermocouple #3 Internal Fault Service required
F54: Thermocouple #4 Internal Fault Service required
F55: Thermocouple #5 Internal Fault Service required
F56: Thermocouple #6 Internal Fault Service required
F57: CJT Sensor Internal Fault Service required
F58: Output Voltage Fault Service required
OM-222 166 Page 36
 Fault Condition Additional Information
F59: Output Current Fault Service required
F60: Temperature Sensor Fault Check control TC connections
Check control TC extension cable
F61: Coolant Flow Fault Check for coolant leak
Clean for coolant blockage
Check coolant filter and level
Check coolant connections
F62: Isolation Fault Check for exposed conductor
Clean for moisture on cables
F63:Line Voltage Fault Check line voltage
F64: Power Source Overtemp Fault Verify power source vents and
wind tunnel are unobstructed
F65: Current Source Fault Service required
F66: Under Freguency Fault Check for loose or open connections
in output cable
F67: Over Frequency Fauit Verify heating cable properly wrapped
Verify material being heated is magnetic
F68: Cable Connection Fault Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
F69: Coolant Overtemp Fault Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
F70: Internal Communication Fault Service required
F71: Internal Thermistor Fault Service required
F72: Coolant Thermistor Fault Service required
F73: Decoupled/Open Coil Service required
F74: Isolation Fault Self-Test Error Service required
F75: Internal Power Supply Fault Service required
F76: Current Source Control Fault Service required
F77: Power Source Internal Comm Fault Service required
F78:Output Current Sense Fault Service required

8-6. System Diagnostic Screens

Additional system diagnostics are available and accessible through the operator interface. Detail operational

parameters can be accessed by pressing and holding the “Run Status” button and pressing the “Parameters”

kW
V
A
Hz
button.

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

OM-222 166 Page 37

 System Diagnostic Screen

RemCmd : 1023 Off Cable 1 : LQD DIAG1

Out I1 : 0A Cable 2 : LQD

Out I2 : 0A ClntFR : 0.75 GPM

Isrc FB : 0A ClrSts : Flowing

RemCmd − This is the value of the remote command from a remote command device which dictates the output
power.
Out I1 − This is the value of the output current on output 1.
Out I2 − This is the value of the output current on output 2.
Isrc FB − This is the value of the amperage in the current source inverter.
Cable 1 − This is the cable type hooked up to output number one. Possible labels:
S AIR − for an air-cooled cable
S LQD − for a liquid-cooled cable
S PLG − for a protective plug
S OPEN − no cable or plug in place
Cable 2 − This is the cable type hooked up to output number two. Possible labels:
S AIR − for an air-cooled cable
S LQD − for a liquid-cooled cable
S PLG − for a protective plug
S OPEN − no cable or plug in place
ClntFR − This is the coolant flow rate (in GPM) from the cooler on a liquid-cooled system.
ClrSts − This is the status of the cooler. Possible labels:
S Off
S Flowing

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

kW
the “Parameters” V
A
Hz
button.

System Diagnostic Screen

VLnA−B : 460V Therm1 : 75 DIAG2

VLnB−C : 460V Therm2 : 75 Therm5 : 75

VLnC−A : 460V Therm3 : 75 ClrTmp : 77

VBus : 650V Therm4 : 75 RmtFlw : Off

VLnA-B − This is the phase to phase line voltage between phases A and B.
VLnB-C − This is the phase to phase line voltage between phases B and C.
OM-222 166 Page 38
VLnC-A − This is the phase to phase line voltage between phases C and A.
VBus − This is the DC bus voltage.
Therm1 − This is the temperature of the current source primary heatsink.
Therm2 − This is the temperature of the bridge heatsink.
Therm3 − This the the temperature of the current source secondary heatsink.
Therm4 − Open (not used).
Therm5 − Open (not used).
ClrTmp − This is the temperature of the coolant on a liquid-cooled system.
S OPEN − no cooler is being used.
RmtFlw − This is the status of the relay contacts for remote coolant flow on a liquid-cooled system.
S OFF
S ON

OM-222 166 Page 39

8-7. Removing Wrapper and Measuring Input Capacitor Voltage
Turn Off power source, and discon-
Y 900 Volts dc can be present on the capacitor bus and
nect input power.
significant DC voltage can remain on capacitors
after unit is Off. Always check the voltage on Remove wrapper.
inverter assembly as shown to be sure the input 1 Current Source Interconnect
Tools Needed: capacitors have discharged before working on unit. Board PC3
5/16 in 2 Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts.
Proceed with job inside unit.
Reinstall wrapper when finished.

+ lead to right bus terminal,

− lead to left bus terminal
2

804 226-A

OM-222 166 Page 40

Notes

OM-222 166 Page 41

 SECTION 9 − ELECTRICAL DIAGRAM

Figure 9-1. Circuit Diagram

OM-222 166 Page 42

 218 057-A

OM-222 166 Page 43

 SECTION 10 − PARTS LIST
5 3 . Hardware is common and
not available unless listed.
4

See Figure 10-3

10 1
9

7
6
11

See Figure 10-2

11
2
804 218-A
Figure 10-1. Wrappers
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-1. Wrappers

... 1 . . . . . . . . . . . . +217 470 .. PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 217 860 .. LABEL, warning electric shock and input pwr (FR) . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . +217 325 .. COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 147 876 .. LABEL, warning general precautionary induction heat . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 217 334 .. PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 217 468 .. DOOR, primary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 . . . . . . . . . . . . . 189 491 .. SPACER, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 168 343 .. HINGE, cont polyolefin copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 222 106 .. BRACKET, mtg fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 196 887 .. FAN, muffin 24VDC 3000 RPM 130 CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 206 270 .. INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-222 166 Page 44

 1 5
. Hardware is common and 4
not available unless listed.

11 12 13
3

9
10

804 219-A

Figure 10-2. Front Panel

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Front Panel

... 1 . . . . . . . . . . . . . 217 323 .. PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 216 225 .. NAMEPLATE, ProHeat 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 216 224 .. PANEL, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 218 686 .. RECEPTACLE ASSY, thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 5 . . . . . . . . . . . . . 217 327 .. PLATE, TC receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 213 060 .. SWITCH, tgl 3pst 60 A 600 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 212 810 .. LABEL, on−off w/symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 221 493 .. LABEL, TC 1−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 115 440 .. STANDOFF, no 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
... 10 . . . . . . . . . . . . . 224 143 .. GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 216 068 .. CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 216 072 .. CIRCUIT CARD ASSY, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 148 297 .. NUT, 006−32 .31 hex .20 stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-222 166 Page 45

 . Hardware is common and 12
not available unless listed.
13 5

10

9
14

1
7
2

4
6

804 220-A
11
Figure 10-3. Rear Panel
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-3. Rear Panel

... 1 . . . . . . . . . . . . . 217 324 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 604 176 .. RECEPTACLE, str dx grd 2P 3W 15 A 125 V . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 127 837 .. RECEPTACLE, tw lk insul fem (dinse type) . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . 089 807 .. CIRCUIT BREAKER, man reset 1P 2.5 A 250 VAC . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 220 824 .. COVER, receptacle weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . +218 689 .. PANEL, rear output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 602 498 .. LABEL, danger high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 143 976 .. RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 047 636 .. HOUSING PLUG+PINS,(service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 221 431 .. CONNECTOR, hermaphroditic panel mount kit . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . . . . 224 042 .. CONNECTOR, circ CPC protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 170 391 .. CONNECTOR, circ MS protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 147 195 .. NUT, 375−27 .54 hex .25 H nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-222 166 Page 46

 . Hardware is common and 18
not available unless listed.

5 4
1
3
2
8

15
16

10 6

14

17
11

10
13
12 804 221-A

Figure 10-4. Base w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 10-4. Base w/Components

... 1 . . . . . . . . . . . . . 217 328 .. FRAME, lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 155 905 .. LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 155 905 .. BUSHING, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . 157 320 .. SCREW, 375−16 x .75 hexwhd .78D GR5 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . 182 414 .. WASHER, flat .406 ID x 0.734 OD x .65 T stl pld . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . . . . . . . . . . 213 865 .. BASE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . 213 939 .. LABEL, warning electric shock can kill significant . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 218 692 .. INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . . . 216 815 .. BRACKET, cap support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 213 870 .. CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . . . . 213 583 .. TRANSFORMER, hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 216 629 .. BRACKET, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 222 728 .. FAN, nuffin 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 14 . . . . . . . . . . . . . . 115 090 .. HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 217 992 .. BAFFLE, air bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . 224 973 .. INSULATOR, lift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 . . . . . . . . . . . . . . 603 115 .. WEATHERSTRIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 . . . . . . . . . . . . . 026 627 .. GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 47
 . Hardware is common and
not available unless listed. See Figure 10-6

11 9

10

3
13
1
7

12

6
14
15

4
2

804 222-A

Figure 10-5. Top Windtunnel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 10-5. Top Windtunnel

... 1 ............. 218 424 .. WINDTUNNEL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ............. 218 684 .. HEAT SINK, AC commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ............. 025 248 .. STANDOFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . . 4
... 4 ............. 222 327 .. THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
... 5 ............. 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
... 6 ............. 605 339 .. WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
... 7 ............. 098 691 .. STAND−OFF,NO 6−32 X .500 LG .250 hex stl m&f . . . . . . . . . . . . . . . . . 6
... 8 ............. 217 326 .. BRACKET, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 ............. 218 691 .. INSULATOR, tank cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 ............. 225 556 .. KIT, circuit card assy intrcnct bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 ............. 216 207 .. CIRCUIT CARD ASSY, TC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 ............. 176 879 .. SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
... 13 ............. 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 14 ............. 225 514 .. FUSE, crtg 2. amp 600 V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 ............. 225 553 .. HOLDER, fuse crtg 30 A 600 V 13/32 X 1−1/2 LG . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 48
 . Hardware is common and
not available unless listed. 2

4
3

804 223-A

Figure 10-6. Capacitor Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-6. Capacitor Assembly

... 1 . . . . . . . . . . . . . 218 685 .. CAPACITOR, popyp met film 1.5 uf 700 VAC . . . . . . . . . . . . . . . . . . . . . . . 4
... 2 . . . . . . . . . . . . . 218 688 .. BUS BAR, tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . . . . . . . . . {221 419 .. SCREW, M8 −1.2 x 12 soc hd−zinc cls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
... 4 . . . . . . . . . . . . . . 602 211 .. WASHER, lock .318 ID X 0.586 OD X .078T STL PLD SPLIT.312 . . . . . . 40
*Recommended Spare Parts.
{Torque screws to 50 in lbs (5.6 N⋅m ).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-222 166 Page 49

 . Hardware is common and
not available unless listed. 6
1

5
4

14

13
9 3
11 10

12 804 224-A

Figure 10-7. Right Windtunnel

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-7. Right Windtunnel

... 1 . . . . . . . . . . . . . 216 630 .. WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 213 873 .. HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 213 871 .. GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . 170 647 .. BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 223 120 .. BLOCK, term 115 amp 3 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 115 443 .. STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 7 . . . . . . . . . . . . . 148 025 .. LUG, univ w/scr 600 V 2/0−6 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 222 326 .. THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
... 10 . . . . . . . . . . . . . 224 391 .. PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 605 339 .. WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . . . . 225 557 .. KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 14 . . . . . . . . . . . . . 176 879 .. SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-222 166 Page 50

 . Hardware is common and 12
not available unless listed. 1

10

2
8
6
13

14

3 15
5

11
9
804 225-A

Figure 10-8. Left Windtunnel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 10-8. Left Windtunnel

... 1 . . . . . . . . . . . . . 216 631 .. WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 213 683 .. HEAT SINK, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 170 647 .. BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . 025 248 .. STAND-OFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . 8
... 5 . . . . . . . . . . . . . . 115 443 .. STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
... 6 . . . . . . . . . . . . . 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
... 7 . . . . . . . . . . . . . 222 327 .. THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 030 170 .. BUSHING, snap-in nyl .750 ID x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 218 430 .. COVER, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 220 825 .. BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . . . . . . . . . . . . 218 687 .. CAPACITOR,polyp film 1.35 uf 700 VAC +5% −0% . . . . . . . . . . . . . . . . 4
... 12 . . . . . . . . . . . . . 219 002 .. TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 225 558 .. KIT, circuit card assy intrcnct I srce out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 217 928 .. CIRCUIT CARD ASSY, power source control . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld slffmg . . . . . . . . . . . . . . . . . . . . . 8

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-222 166 Page 51
Notes
Notes
Notes
 Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory Kits
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue® Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturer’s warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is * Inverters (input and output rectifiers only)
standards, or equipment which has not had reasonable
there to help you, every and necessary maintenance, or equipment which has
step of the way. 2. 3 Years — Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods at
3. 1 Year — Parts and Labor Unless Specified customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue® for the remaining warranty period of the from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 1/05
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05