OM-171 006E

January 2005

Processes
Induction Heating

Description

Induction Heating Power Source

IHPS II 5 KW

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 dont have time to do
it any other way.
Thats 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 couldnt afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres 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 catalog 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 7/03

Working as hard as you do

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

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de lappareil. . . . . . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Connecting Head/Coil To Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Remote 14 Receptacle RC14 Information And Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Power Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Power Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Ground Fault Test Switch And Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Sequence Of Induction Heating Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Automatic Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Safety Interlock Switch And Measuring Tuning Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Tuning Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som _8/03

1-1. Symbol Usage

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.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

1-2. Arc Welding Hazards

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

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

Y During operation, keep everybody, especially children, away.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.

D Keep your head out of the fumes. Do not breathe the fumes.

D Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first double-check connections.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not drape cables over your body.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
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 welded.

OM-171 006 Page 1

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.

MAGNETIC FIELDS can affect pacemakers.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.

OM-171 006 Page 2

D Pacemaker wearers keep away.

D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

MOVING PARTS can cause injury.

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

combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards
closed and securely in place.

FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.

D
D

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

navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment 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, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.

D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.

D
D

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.

D
D

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

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

For Gasoline Engines:

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

Y Battery posts, terminals and related accessories contain lead

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

For Diesel Engines:

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

OM-171 006 Page 3

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

8004636727 or in Toronto 4167474044, website: www.csainternational.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 100368002 (phone: 2126424900,
website: www.ansi.org).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (phone: 6177703000, website: www.nfpa.org and www.
sparky.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:
6177703000,website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 222024102 (phone: 7034120900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Officesphone for Region 5, Chicago, is
3123532220,website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:

OM-171 006 Page 4

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT

UTILISATION
som_fre 8/03

2-1. Signification des symboles

Signifie Mise en garde. Faire preuve de vigilance.
Cette procdure prsente des risques identifis par les
symboles adjacents aux directives.
Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde. Faire preuve de vigilance. Il y a des dangers lis aux CHOCS LECTRIQUES, aux
PICES EN MOUVEMENT et aux PICES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.

2-2. Dangers relatifs au soudage larc

Y Les symboles ci-aprs sont utiliss tout au long du prsent
manuel pour attirer lattention sur les dangers potentiels et les
identifier. Lorsquon voit un symbole, faire preuve de vigilance et
suivre les directives mentionnes afin dviter tout danger. Les
consignes de scurit nonces ci-aprs ne font que rsumer le
contenu des normes de scurit mentionnes la section 2-5.
Lire et respecter toutes ces normes.
Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies.
Y Pendant lutilisation de lappareil, tenir lcart toute personne,
en particulier les enfants.

LES DCHARGES LECTRIQUES

peuvent tre mortelles.
Un simple contact avec des pices sous tension peut
causer une lectrocution ou des blessures graves.
Llectrode et le circuit de soudage sont sous tension
ds que lappareil est en fonctionnement. Le circuit
dentre et les circuits internes de lappareil sont galement sous tension.
En soudage semiautomatique ou automatique, le fil, le dvidoir, le
logement des galets dentranement et les pices mtalliques en contact
avec le fil de soudage sont sous tension. Tout matriel mal install ou mal
mis la terre prsente un danger.
D Ne jamais toucher aux pices lectriques sous tension.
D Porter des gants et des vtements de protection secs et exempts de
trous.
D Sisoler de la pice et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empcher tout contact
physique avec la pice ou la terre.
D
D
D

Ne pas se servir dune source de courant alternatif dans les zones humides, les endroits confins ou l o on risque de tomber.
Ne se servir dune source de courant alternatif QUE si le procd de soudage lexige.
Si lutilisation dune source de courant alternatif savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Couper/tiqueter
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de scurit).
D Installer et mettre la terre correctement lappareil conformment
son manuel dutilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la
borne de terre du sectionneur ou que la fiche du cordon est raccorde
une prise correctement mise la terre.
D Pour excuter les branchements dentre, fixer dabord le conducteur
de mise la terre adquat et contrevrifier les connexions.
D Vrifier frquemment le cordon dalimentation et sassurer quil nest
ni endommag ni dnud ; le remplacer immdiatement sil est endommag tout cble dnud peut causer une lectrocution.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou
mal pisss.
D Ne pas senrouler les cbles autour du corps.
D Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct.
D Ne pas toucher llectrode quand on est en contact avec la pice, la
terre ou une lectrode dune autre machine.

D Nutiliser que du matriel en bon tat. Rparer ou remplacer surle

champ les pices endommages. Entretenir lappareil conformment
au prsent manuel.
D Porter un harnais de scurit quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le cble de retour de faon obtenir un bon contact mtal sur
mtal avec la pice souder ou la table de travail, le plus prs possible
de la soudure.
D

Ne pas connecter plus dune lectrode ou plus dun cble de masse un

mme terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANT

dans les convertisseurs aprs la suppression de
lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions
nonces la section Entretien avant de toucher les pices.

LES FUMES ET LES GAZ peuvent

tre dangereux.
Le soudage gnre des fumes et des gaz dont
linhalation peut tre dangereuse pour la sant.

D Se tenir distance des fumes et ne pas les inhaler.

D lintrieur, ventiler la zone et/ou utiliser un dispositif daspiration au
niveau de larc pour lvacuation des fumes et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur adduction
dair agr.
D Lire les fiches techniques de santscurit (FTSS) et les instructions du fabricant concernant les mtaux, les consommables, les
revtements, les nettoyants et les dgraisseurs.
D Ne travailler dans un espace clos que sil est bien ventil ou porter un
respirateur adduction dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage
peuvent se substituer lair, abaisser la teneur en oxygne et causer
des lsions ou des accidents mortels. Sassurer que lair est respirable.
D Ne pas souder proximit doprations de dgraissage, de nettoyage
ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en
prsence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de mtaux munis dun revtement, tels que la tle
dacier galvanise, plombe ou cadmie, moins que le revtement
nait t enlev dans la zone de soudage, que lendroit soit bien ventil, et si ncessaire, porter un respirateur adduction dair. Les
revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques lorsquon les soude.

OM-171 006 Page 5

LES RAYONS DE LARC peuvent causer des brlures oculaires et cutanes.

Le rayonnement de larc gnre des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brlures oculaires et cutanes.
Des tincelles sont projetes pendant le soudage.
D Porter un masque de soudage muni dun filtre de la nuance adquate
pour se protger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de scurit ANSI Z49.1 et Z87.1).
D Porter des lunettes de scurit crans latraux sous le masque.
D Utiliser des crans ou des barrires pour protger les tiers de lclat
blouissant ou aveuglant de larc ; leur demander de ne pas regarder
larc.
D Porter des vtements de protection en matire durable et ignifuge
(cuir ou laine) et des chaussures de scurit.

LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectu sur des rcipients ferms tels que
des rservoirs, des fts ou des conduites peut causer
leur clatement. Des tincelles peuvent tre projetes
de larc de soudure. La projection dtincelles, les
pices chaudes et les quipements chauds peuvent causer des
incendies et des brlures. Le contact accidentel de llectrode avec tout
objet mtallique peut causer des tincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vrifier et
sassurer que lendroit ne prsente pas de danger.
D Se protger et protger les tiers de la projection dtincelles et de mtal chaud.
D Ne pas souder un endroit o des tincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables une distance de 10,7 m
de larc de soudage. En cas dimpossibilit, les recouvrir soigneusement avec des protections agres.
D Des tincelles et des matires en fusion peuvent facilement passer
mme par des fissures et des ouvertures de petites dimensions.
D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.
D Le soudage effectu sur un plafond, un plancher, une paroi ou une
cloison peut dclencher un incendie de lautre ct.
D Ne pas souder des rcipients ferms tels que des rservoirs, des fts
ou des conduites, moins quils naient t prpars conformment
lAWS F4.1 (voir les normes de scurit).
D Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques dlectrocution et dincendie.
D Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
D En cas de non utilisation, enlever la baguette dlectrode du porte
lectrode ou couper le fil au raz du tubecontact.
D Porter des vtements de protection exempts dhuile tels que des
gants en cuir, une chemise en tissu pais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
quun briquet au butane ou des allumettes.

LES PARTICULES PROJETES peuvent blesser les yeux.

D Le soudage, le burinage, le passage de la pice
la brosse mtallique et le meulage provoquent
lmission dtincelles et de particules mtalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D

Porter des lunettes de scurit crans latraux agrs, mme sous le

masque de soudage.

OM-171 006 Page 6

LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou mme

la mort.
Couper lalimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours bien ventiler les espaces confins ou porter un respirateur adduction dair agr.
D

LES PICES CHAUDES peuvent causer des brlures graves.

D Ne pas toucher les pices chaudes main nue.
D Prvoir une priode de refroidissement avant
dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuvent

perturber le fonctionnement des stimulateurs cardiaques.
D
D

Les personnes qui portent un stimulateur cardiaque

doivent se tenir distance.
Ils doivent consulter leur mdecin avant de sapprocher dun lieu o on excute des oprations de soudage larc, de gougeage ou de soudage par points.

LE BRUIT peut affecter loue.

Le bruit de certains processus et quipements peut
affecter loue.
D

Porter des protecteurs doreille agrs si le niveau

sonore est trop lev.

Les BOUTEILLES
peuvent exploser.

endommages

Les bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Toute bouteille endommage
peut exploser. Comme les bouteilles de gaz font
normalement partie du procd de soudage, les
manipuler avec prcaution.
D Protger les bouteilles de gaz comprim de la chaleur excessive, des
chocs mcaniques, du laitier, des flammes nues, des tincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un portebouteilles pour les empcher de tomber ou de se
renverser.
D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une lectrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression elle
risquerait dexploser.
D Nutiliser que les bouteilles de gaz protecteur, rgulateurs, tuyaux et
raccords adquats pour lapplication envisage ; les maintenir en bon
tat, ainsi que les pices connexes.
D Dtourner la tte lorsquon ouvre la soupape dune bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publications P1 de la CGA,
mentionnes dans les normes de scurit.

2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de

lappareil.
Risque DINCENDIE OU DEXPLOSION

LES ORGANES MOBILES peuvent

causer des blessures.

D Ne pas placer lappareil sur une surface inflammable, ni audessus ou proximit delle.

D Se tenir lcart des organes mobiles comme les

ventilateurs.
D Maintenir ferms et bien fixs les portes,
panneaux, recouvrements et dispositifs de
protection.

D Ne pas installer lappareil proximit de produits inflammables.

D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionne et protge avant de mettre
lappareil en service.

LA CHUTE DE LAPPAREIL peut

blesser.
D Nutiliser que lanneau de levage pour lever lappareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacit adquate pour lever
lappareil.
D Si on utilise un chariot lvateur pour dplacer lunit, sassurer que
les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.

LEMPLOI EXCESSIF peut FAIRE

SURCHAUFFER LQUIPEMENT.
D Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal.
D Rduire le courant ou le cycle opratoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer lalimentation en air du poste.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pices.
D Utiliser des pochettes et des botes antistatiques
pour stocker, dplacer ou expdier des cartes de
circuits imprims.

LES PICES MOBILES peuvent causer des blessures.

D Se tenir lcart des pices mobiles.
D Se tenir lcart des points de coincement tels
que les dvidoirs.

LES FILS DE SOUDAGE peuvent causer des blessures.

D Ne pas appuyer sur la gchette avant den avoir
reu linstruction.
D Ne pas diriger le pistolet vers soi, vers dautres
personnes ou vers toute pice mcanique en engageant le fil de soudage.

LE RAYONNEMENT HAUTE FRQUENCE (H. F.) risque de causer des

interfrences.
D Le rayonnement haute frquence peut causer
des interfrences avec les quipements de radionavigation et de communication, les services de
scurit et les ordinateurs.
D Ne demander qu des personnes qualifies familiarises avec les
quipements lectroniques de faire fonctionner linstallation.
D Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences causes par linstallation.
D Si la Federal Communications Commission signale des interfrences, arrter immdiatement lappareil.
D Faire rgulirement contrler et entretenir linstallation.
D Maintenir soigneusement ferms les panneaux et les portes des sources de haute frquence, maintenir le jeu dclatement au rglage
adquat et utiliser une terre et un blindage pour rduire les interfrences ventuelles.

LE SOUDAGE LARC peut causer

des interfrences.
D Lnergie lectromagntique peut causer des
interfrences avec lquipement lectronique
sensible tel que les ordinateurs et lquipement
command par ordinateur tel que les robots.
D Veiller ce que tout lquipement de la zone de soudage soit compatible au point de vue lectromagntique.
D Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : terre).
D Veiller souder une distance de 100 mtres de tout quipement
lectronique sensible.
D Veiller ce que le poste de soudage soit pos et mis la terre conformment au prsent manuel.
D En cas dinterfrences aprs excution des directives prcdentes, il
incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds,
lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez distance.
D Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

OM-171 006 Page 7

2-4. Proposition californienne 65 Avertissements

Y Les quipements de soudage et de coupage produisent des
fumes et des gaz qui contiennent des produits chimiques
dont ltat de Californie reconnat quils provoquent des
malformations congnitales et, dans certains cas, des
cancers. (Code de sant et de scurit de Californie,
chapitre 25249.5 et suivants)

Pour les moteurs essence :

Y Les batteries, les bornes et autres accessoires contiennent du

plomb et des composs base de plomb, produits chimiques
dont ltat de Californie reconnat quils provoquent des
cancers et des malformations congnitales ou autres
problmes de procration. Se laver les mains aprs manipulation.

Pour les moteurs diesel :

Y Les gaz dchappement des moteurs contiennent des

produits chimiques dont ltat de Californie reconnat quils
provoquent des cancers et des malformations congnitales
ou autres problmes de procration.

Y Les gaz dchappement des moteurs diesel et certains de

leurs composants sont reconnus par ltat de Californie
comme provoquant des cancers et des malformations congnitales ou autres problmes de procration.

2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(tlphone : (305) 4439353, site Web : www.aws.org).

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800)

4636727 ou Toronto : (416) 7474044, site Web : www.csainternational.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (tlphone : (305) 4439353, site Web : www.aws.org).

Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West
42nd Street, New York, NY 100368002 (tlphone : (212) 6424900,
site Web : www.ansi.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org et
www.sparky.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P1,

de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de lU.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312)
3532220, site Web : www.osha.gov).

2-6. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et les effets des champs magntiques basse frquence sur lorganisme
En parcourant les cbles de soudage, le courant cre des champs lectromagntiques. Les effets potentiels de tels champs restent
proccupants. Cependant, aprs avoir examin plus de 500 tudes qui
ont t faites pendant une priode de recherche de 17 ans, un comit
de spcialistes du National Research Council a conclu : Laccumulation de preuves na pas dmontr que lexposition aux champs
magntiques et aux champs lectriques haute frquence constitue un
risque pour la sant humaine . Toutefois, les tudes et lexamen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de rduire lexposition aux champs
lectromagntiques pendant le soudage ou le coupage.

OM-171 006 Page 8

Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes :
1. Garder les cbles ensemble en les torsadant ou en les fixant avec du
ruban adhsif.
2. Mettre tous les cbles du ct oppos loprateur.
3. Ne pas senrouler les cbles autour du corps.
4. Garder le poste de soudage et les cbles le plus loin possible de soi.
5. Placer la pince de masse le plus prs possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.

SECTION 3 SPECIFICATIONS
Type of
Input Power

Three-Phase,
230 Or 460
Volts AC,
50/60 Hz

Output
Frequency

Rated
Output

10 To 50 kHz

5 kW At 100%
Duty Cycle;
Max 200 A
(RMS), 350 V
(RMS)

Required
Reflective
Inductance

5 to 30 h

Input
Amperes At
Rated Output

KVA/KW
Used At
Rated Output

22 A At 230 V
*0.6 A;
11 A At 460 V
*0.3 A

8.5 kVA/6.3 kW
*0.15 kVA/0.146
kW

Overall
Dimensions
Length: 19-1/2
in (495 mm)
Width: 11-1/2 in
(292 mm)
Height: 11-3/4 in
(298 mm)

Weight

Net: 65 lb
(29.5 kg)
Ship: 70 lb
(31.8 kg)

*While idling

SECTION 4 INSTALLATION
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.

4-1. Connecting Head/Coil To Power Source

1
2
3

Rear Panel

Output Receptacle RC15

Plug From Head/Coil
Threaded Collar

Receptacle RC15 is a 4-socket

receptacle.

3
2

To connect to receptacle, align keyway, insert plug, and tighten

threaded collar.

Socket Information:
A, C

Approx. 350 volts ac, 10 to 50 kHz RMS highfrequency output

B, D

Approx. 350 volts ac, 10 to 50 kHz RMS highfrequency output

802 663

OM-171 006 Page 9

4-2. Remote 14 Receptacle RC14 Information And Connection

1

1
2
3
4

To connect to receptacle, align keyway, insert plug, and tighten

threaded collar.

3
4
B

Plug
Threaded Collar
Keyway
Remote 14 Receptacle RC14
(See Section 4-3)

H
C L N
D M
G
E F
4

sb7.1* 3/93 - Ref. S-0004-A / Ref. S-0750 / Ref. 802 663

4-3. Remote 14 Socket Information

Socket
Remote
Contactor

A
B

H
C L N
D M
G
E F
4

Remote
Output
Control
Power
Source
Fault

Remote
Metering

OM-171 006 Page 10

Socket Information

+24 volts dc.

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

Command reference; +10 volts dc.

Control circuit common.

Input command signal (potentiometer wiper or 0 to +10 volts dc).

Not used.

F,J

Absence of internal contact closure between F and J signals power source failure to remote control device.

Coil loss compensation value.

Actual frequency output signal (1 volt/5 kHz).

Average power output signal (1 volt/1 kW).

Voltage
g output
p signal
g
RMS (1
( volt/50
/ volts).
)

Current output
p signal
g
RMS (1
( volt/50 amperes).
p
)

Chassis common.

4-4. Positioning Jumper Links

Turn Off unit Power switch, and disconnect input power.
Jumper links allow operation on different input voltages and are factory set for the highest input voltage.
Check input voltage available at
site.
Remove wrapper to check jumper
links.
1
2
3

Terminal Strip TE2

Input Voltage Jumper Link
Input Voltage Label

Four jumper links supplied. Look at

jumper links and compare link
position with label.
Move links to match input voltage.
For example, use 230 volts position
on label when 230 volts input power
is available.

Reinstall wrapper or go on to
Section 4-5.

230

460

230

230

460 230
S-170 603-A

Tools Needed:

5/16 in

Ref. 802 664

OM-171 006 Page 11

4-5. Connecting Input Power

Have only qualified persons make
this installation.
Remove wrapper.
1

Line Disconnect Device Of

Proper Rating

Obtain and install line disconnect

device.

2
3

Input Conductors
Grounding Conductor

Select size and length using

Section 4-6. Conductor rating must
comply with national, state, and local electrical codes.
1
6

5
2
3

Disconnect Device Ground

Terminal

Install and connect grounding

conductor and input conductors in
conduit
or
equivalent
to
deenergized
line
disconnect
device.
Connect grounding conductor first,
then line input conductors.
Be sure grounding conductor goes
to an earth ground.
Reinstall wrapper.
5

Overcurrent Protection

Select type and size using Section

4-6. Install into deenergized line
disconnect
device
(fused
disconnect switch shown).
6

Unit Fuse Block

Internal replacement fuses:

230 V FWC25A10F
460 V FWC16A10F

Tools Needed:

5/16 in
Ref. 802 664

4-6. Electrical Service Guide

Input Voltage

230

460

Input Amperes At Rated Output

22

11

30

15

10

14

200
(61)

318
(97)

10

14

Max Recommended Standard Fuse Rating In Amperes 1

Normal Operating 2
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil

Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.
2 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).
OM-171 006 Page 12

SECTION 5 OPERATION
5-1. Controls
1
2
3
4

Power Adjust Control

Remote Power Control Switch
Ground Fault Test Switch And
Ground Fault LED
Power Switch

2
3

4
Ref. 802 662

5-2. Safety Equipment

1
2
1

Insulating Gloves
Safety Glasses With Side
Shields

Wear dry insulating gloves and

safety glasses with side shields.

sb3.1* 10/91

5-3. Power Adjust Control

1

Power Adjust Control

Use control to select power

between the minimum and
maximum output of the power
source. The numbers around the
control are in kilowatts (kW).

Ref. 168 461-C

OM-171 006 Page 13

5-4. Remote Power Control Switch

1

Remote Power Control Switch

Use switch to select way of

controlling unit output.
1

For front panel control, place switch

in Panel position.
For remote control, place switch in
Remote 14 position. Connect
controller or pendant control to
Remote 14 receptacle (see Section
4-2).

5-5. Power Switch

1
2

Power Switch
Pilot Light

Use switch to turn unit, fan motor,

and pilot light On and Off.

Unit is ready to heat 10 seconds

after Power switch is placed in On
position.

5-6. Ground Fault Test Switch And Indicator Light

1

PRESS
TO
TEST

Ground Fault Test Switch

Use switch to test ground fault

circuitry.

1
FAULT

Ground Fault Indicator Light

Light comes on when circuitry

detects a ground fault.
GROUND FAULT

5-7. Sequence Of Induction Heating Process

Install & Connect

Power Source

Install & Connect

Induction
Head/Coil

Install & Connect

Coolant Supply,
If Required

Put On
Personal Safety
Equipment

Turn On
Coolant Supply,
If Required

Set
Controls

Position Work
Near
Head/Coil

Turn On
Power
Switch

Wait
10 Seconds

Unit Ready
To Heat

OM-171 006 Page 14

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance
Y Disconnect power
before maintaining.

. Maintain more often

during severe conditions.

3 Months
Clean And
Tighten Output
Connections

Repair Or Replace
Cracked Output
Cables

6 Months
Replace
Damaged Or
Unreadable
Labels

Blow Out Or
Vacuum Inside

OM-171 006 Page 15

6-2. Overload Protection

1

Y Turn Off and disconnect

input power before checking
fuses.
1

Unit Fuse Block And Fuses

F1, F2, And F3 (See Section
4-6 For Rating)

Fuses F1, F2, and F3 protect unit

from overload. If fuse(s) opens, the
power source shuts down.
Replace fuses as needed. Use
proper tool when removing fuses.
Reinstall wrapper.
2

Fuse F4 (See Parts List For

Rating)

Fuse F4 protects +24 volts dc

circuit from overload. If fuse opens,
+24 volts dc output at receptacle
RC14 stops. Replace F4.

Tools Needed:

5/16 in

Ref. 802 664 / Ref. 802 663

6-3. Overheating Protection

Thermostat TP1 protects the unit from damage due to overheating. If main heat sink gets too hot, TP1 opens and
output stops. The fan keeps running to cool the heat sink. Wait several minutes before trying to heat.

6-4. Automatic Shutdown Protection

This unit automatically shuts down upon sensing certain fault conditions, such as an out-of-range frequency condition,
short circuit load condition, or an open circuit (no load) condition. The unit also has automatic voltage limiting and
power ratio limiting, which limits the output power based on improper load impedance.

OM-171 006 Page 16

6-5. Ground Fault Protection

Ground fault 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 must be

connected between the workpiece
and power source to provide
proper ground fault protection
from a short in the output circuit.
1
2
3

Power Source
Receptacle
Plug

To connect plug, align key with keyway, insert end into receptacle, and
rotate plug until tight.
4
5
6

Handle
Magnet
Workpiece

Use handle to place magnet on the

workpiece.

802 678 / Ref. 802 665

OM-171 006 Page 17

6-6. Safety Interlock Switch And Measuring Tuning Capacitor Voltage

1
1

Tuning Capacitor Cover

The cover prevents exposure of the

tuning capacitors on the unit.
2

Safety Interlock Switch

(Behind Cover)

The safety interlock switch

prevents the contactor from
energizing with the cover open.

To measure capacitor voltage, turn

off power source and disconnect
input power.
2

Open tuning capacitor cover.

3
4

Tuning Capacitor Assembly

Voltmeter

Measure voltage across busbars

every 30 seconds until voltage is
near 0 (zero) volts.

3
Significant AC voltage can remain on
capacitors after unit is Off. Always
check capacitors as shown to be sure
they have discharged before working
on unit.

Proceed with job near tuning

capacitor assembly. Close and
secure cover when finished.

Tools Needed:
5/16 in

Ref. 802 663

6-7. Measuring Input Capacitor Voltage

Turn Off power source
disconnect input power.

and

Remove wrapper.

Significant DC voltage can remain on

capacitors after unit is Off. Always
check ALL capacitors as shown to be
sure they have discharged before
working on unit.

1
2
3

Input Capacitor C1
Input Capacitor C2
Voltmeter

Check input capacitor(s).

Measure the dc voltage across the
positive (+) and negative ()
terminals every 30 seconds until
voltage is near 0 (zero) volts.
Proceed with job inside unit.
Reinstall wrapper when finished.

Tools Needed:
5/16 in

OM-171 006 Page 18

800 998-C

6-8. Troubleshooting
Y Disconnect power before troubleshooting

Trouble

Remedy

No heat output.

Replace building line fuses, reset circuit breaker, or replace unit fuse(s) F1, F2, and/or F3
(see Section 4-5).
Secure head/coil plug in power source receptacle (see Section 4-1).
Check and replace Power switch if necessary.
Connect power source to proper input voltage or check for low line voltage
(see Sections 4-4 and 4-5).

No heat output; fan motor continues to Tuning capacitor cover safety interlock switch open. Close tuning capacitor cover
run.
(see Section 6-6).
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit
has cooled (see Section 6-3).
Low heat output.

Check tuning of induction heating output system (see Section 6-9).

No +24 volts dc output at 14-socket Check fuse F4, and replace if necessary (see Section 6-2).
receptacle.

6-9. Tuning Chart

CAUTION
ENERGIZING CONTACTOR WITHOUT ALL 3 TUNING CAPACITORS IN OUTPUT CIRCUIT will damage power source.

DO NOT operate power source without all 3 tuning capacitors in output circuit.

Voltage*

Current (Amperage)*

Frequency (KHz)

Corrective Action

High

Low

Low

Lower inductance or decrease matching transformer turns ratio

High

Low

High

Add capacitance

High

Low

Mid-Range

Low

High

Low

Lower capacitance

Low

High

High

Increase matching transformer turns ratio, or lower capacitance and

increase inductance

Low

High

Mid-Range

Decrease matching transformer turns ratio and add capacitance

Increase matching transformer turns ratio and lower capacitance

*High voltage > 300 V rms; Low voltage < 200 V rms; Operating current range: 0 to 200 A rms

OM-171 006 Page 19

SECTION 7 ELECTRICAL DIAGRAM

Figure 6-1. Circuit Diagram For Induction Heating Power Source

OM-171 006 Page 20

218 030-A

OM-171 006 Page 21

OM-171 006 Page 22

60

10

Figure 8-1. Complete Assembly

67

59

65

71
70
69
68

11

66

61

12

58

63

62

64

16
13 15
14

57

17

18

54

19

20

55

21

22

56

23

50
51

25

52
53

24

28

27

49

26

48

29
30

47

31

72

46

33

32

36

37

34

35

45

43

42

41

40

39

38

44

SECTION 8 PARTS LIST

. Hardware is common and

not available unless listed.

802 666-A

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Complete Assembly

. . . 1 . . . . . . . . . . . . . 141 690
. . . 2 . . . . PC1 . . . 199 452
. . . . . . . . . . PLG1 . . . 152 249
. . . . . . . . . . PLG2 . . . 158 720
. . . . . . . . . PLG3-5 . 148 439
. . . . . . . . . . PLG6 . . . 164 899
. . . 3 . . . . . . . . . . . . . 147 507
. . . 4 . . . . TE2 . . . 186 782
. . . . . . . . . . . . . . . . . . . 186 783
. . . 5 . . . . . . . . . . . . . 145 453
. . . 6 . . . . . . . . . . . . . 099 037
. . . 7 . . . . . . . . . . . . . 136 190
. . . 8 . . . . C1,2 . . . 151 281
. . . . . . . . . . . . . . . . . . . 155 517
. . . 9 . . . . . . . . . . . . . 006 426
. . . . . . . . . . . . . . . . . . . 148 297
. . . 10 . . . . . . . . . . . . . 171 007
. . . 11 . . . . CR1 . . . 106 462
. . . 12 . . . . . R1 . . . . 073 562
. . . 13 . . . . F1-3 . . . 194 419
. . . 13 . . . . F1-3 . . . 193 027
. . . 14 . . . . . . . . . . . . . 186 778
. . . 15 . . . . RC15 . . . 169 835
. . . . . . . . . . . . . . . . . . . 167 723
. . . 16 . . . . RC14 . . . 143 976
. . . 17 . . . . . . . . . . . . . 186 834
. . . . . . . . . . . . . . . . . . . 126 026
. . . 18 . . . . . . . . . . . . . 174 048
. . . . . . . . . . CT1 . . . 166 578
. . . . . . . . . . CT2 . . . 162 854
. . . . . . . . . . CT3 . . . 161 309
. . . . . . . . . . CT4 . . . 168 522
. . . 19 . . . . . . . . . . . . . 046 432
. . . . . . . . . . . F4 . . . . 012 643
. . . 20 . . . . . . . . . . . . . 145 743
. . . 21 . . . . . . . . . . . . . 010 916
. . . 22 . . . . . . . . . . . . . 026 947
. . . . . . . . . . . . . . . . . . . 038 776
. . . 23 . . . . . . . . . . . . . 167 887
. . . 24 . . . . C3-5 . . . 132 844
. . . 24 . . . . C3-5 . . . 170 867
. . . 25 . . . . . D11 . . . 197 854
. . . 26 . . . . . . . . . . . . . 200 408
. . . 27 . . . . . . . . . . . . +170 414
. . . . . . . . . . . . . . . . . . . 127 363
. . . 28 . . . . PC2 . . . 169 810
. . . . . . . . . PLG10 . . 168 847
. . . 29 . . . . R16 . . . 170 624
. . . 30 . . . . PC3 . . . 169 814
. . . 31 . . . D5-7,9 . . 170 565
. . . 32 . . . . Q5,6 . . . 163 472
. . . 33 . . . . TP1 . . . 006 334
. . . 34 . . . . SR1 . . . 131 828
. . . 35 . . . . . . . . . . . . . 024 103
. . . 36 . . . . . . . . . . . . . 126 416
. . . 37 . . . . . . . . . . . . . 126 415
. . . 38 . . . . . . . . . . . . +167 886
. . . . . . . . . . . . . . . . . . . 147 876

. . GROMMET, scr No. 8/10 panel hole .281sq .197 high . . . . . . . . . . . . . . . .

. . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATION, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 9P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper slotted 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EDGE TRIM, style 62-1/16 black w/clips (order by ft) . . . . . . . . . . . . . . . . .
. . NUT, 10-32 push on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 1600uf 400VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, set 10-32 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 10-32 push on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer 1.670dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg 25A 600V semiconductor (230VAC operation) . . . . . . . . . . . .
. . FUSE, crtg 16A 600V semiconductor (460VAC operation) . . . . . . . . . . . .
. . BLOCK, fuse 600V 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE, w/lead (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ ms/met 4skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CASE SECTION, front/bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, current (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr .250 x 1.250 panel mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, mintr gl slo-blo 1A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LUG, univ w/scr 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp film 2.1uf 1000VDC (used with 903 439) . . . . . . . . . .
. . CAPACITOR, polyp film 1.5uf 1000VDC (used with 903 439-01-1,
903 439-01-3, 903 628-01-1, 903 628-01-2) . . . . . . . . . . . . . . . . . . . . . . . . .
. . LED, red 2.1V 20 ma 45.0 mcd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE, fast recovery 30A 1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSISTOR, IGBT module 75A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 100A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap-in nyl .750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, molded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
1
1
1
3
1
1
1
4
1
1ft
8
2
4
2
2
1
1
1
3
3
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
4
4
2
3
3
1
1
1
1
1
1
1
1
5
2
1
1
1
1
1
1
1

OM-171 006 Page 23

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Complete Assembly (Continued)

. . . 39 . . . . . . . . . . . . . 161 330 . .
. . . 40 . . . . . . . . . . . . . 169 325 . .
. . . . . . . . . . . . . . . . . . . 176 933 . .
. . . 41 . . . . . . . . . . . . . 161 330 . .
. . . 42 . . . . . . . . . . . . . 148 828 . .
. . . 43 . . . . . FM . . . . 170 692 . .
. . . 44 . . . . . . . . . . . . . 170 694 . .
. . . 45 . . . . . . . . . . . . . 605 525 . .
. . . 46 . . . . . D8 . . . . 168 413 . .
. . . 47 . . . . Q1-4 . . . 171 883 . .
. . . 48 . . . . . Z1 . . . . 168 510 . .
. . . 49 . . . . . T3 . . . . 189 295 . .
. . . 50 . . . . . S3 . . . . 027 878 . .
. . . 51 . . . . . . . . . . . . . 199 830 . .
. . . 52 . . . . . S1 . . . . 091 441 . .
. . . 53 . . . . . . . . . . . . . 153 664 . .
. . . 54 . . . . T1,2 . . . 170 475 . .
. . . 55 . . . . . . . . . . . . . 198 035 . .
. . . 56 . . . . . . . . . . . . . 197 931 . .
. . . 57 . . . . . . . . . . . . . 197 900 . .
. . . 58 . . . . . . . . . . . . . 193 329 . .
. . . 59 . . . . . . . . . . . . . 143 915 . .
. . . 60 . . . . . . . . . . . . . 193 332 . .
. . . 61 . . . . . . . . . . . . . 127 837 . .
. . . 62 . . . . . . . . . . . . . 127 836 . .
. . . 63 . . . . . . . . . . . . . 193 506 . .
. . . 64 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . 196 854 . .
. . . 66 . . . . . . . . . . . . . 199 829 . .
. . . 67 . . . . . . . . . . . . . 052 964 . .
. . . 68 . . . . . . . . . . . . . 193 506 . .
. . . 69 . . . . . PL1 . . . 170 599 . .
. . . 70 . . . . . . . . . . . . . 199 672 . .
. . . 71 . . . . . S2 . . . . 120 376 . .
. . . 72 . . . . . C6 . . . . 201 717 . .

BAR, support heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAR, support heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 6.500 5wg 30deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, .312-24 stl elastic stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, fast recovery 60A 1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSISTOR, mosfet 71A 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, lim 15A 125/250VAC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, switch safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, tgl 3PST 40A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, pwr main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNET, permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, work ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNT, sgl stud 1.5dia x 1.000 lg .312-18 . . . . . . . . . . . . . . . . . . . . . . . . .
CASE SECTION, bottom filter enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, tw lk insul fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUG, tw lk insul male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, .312-18 x 2.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, ground fault control . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, board ground fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 24VDC DPDT 10A/120VAC . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, .312-18 x 2.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHT, ind wht lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
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1
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1

PLG3 Included w/CT1-4/PLG5 Included w/PC2

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-171 006 Page 24

Notes

Notes

Effective January 1, 2004

(Equipment with a serial number preface of LE or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

LIMITED WARRANTY Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Induction Heating Coils and Blankets

APT & SAF Model Plasma Cutting Torches

Remote Controls

Accessory Kits

Replacement Parts (No labor)

Spoolmate Spoolguns

Canvas Covers

Within the warranty periods listed below, Miller will repair or

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

Millers True Blue Limited Warranty shall not apply to:

1.

Miller shall honor warranty claims on warranted equipment

listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.

Consumable components; such as contact tips,

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

2.

Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.

3.

Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.

1.

5 Years Parts 3 Years Labor

*
*
2.

3 Years Parts and Labor

*
*
*
*

3.

Original main power rectifiers

Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)

Water Coolant Systems (Integrated)

*
*
*

Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)

1 Year Parts and Labor Unless Specified

*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year whichever is greater.)

4.

6 Months Batteries

5.

90 Days Parts

MIG Guns/TIG Torches

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customers risk and expense. Millers option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04

Owners 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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair

Miller Electric Mfg. Co.

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

Replacement Parts
Training (Schools, Videos, Books)

International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams

European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

Welding Process Handbooks

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 manufacturers
Transportation Department.

PRINTED IN USA

2004 Miller Electric Mfg. Co.

1/04