Miller IH XFMR4 Owner's manual

Miller
Brand
Miller
Model
IH XFMR4
Category
Welding System
Type
Owner's manual

This manual is also suitable for

1/
~MiIIer
February
1992
FORM:
OM-148
109
Effective
With
Serial
No.
KC211335
MODEL:
IHPS4
25-50
IH
XFMR4
lc~
ALE
COPY
RETUR1\~
TO
FOLDER
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safe~
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
induction
heating
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
factory
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
MISer
Group
Ltd.,
Company
~
BOX
1079
Appleton,
WI
54912
USA
Tel.
414-734.9821
coven
1/92ST.151
874
PRINTED
IN
USA
I
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.
Appleton.
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points.
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
. .
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor.
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods.
the
exclusive
remedies
therefore
shall
be,
at
MILLERs
option
(1)
repair
or
(2)
replace
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB..
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure.
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOP
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No.
Date
of
Purchase
m,IIe,
8191
INDUCTION
HEATING
SAFETY
PRECAUTIONS
Below
are
examples
of
the
precautionary
labels
found
on
the
power
source,
the
controller,
and
the
head
assembly.
Any
person
who
installs
operates,
maintains,
or
services
this
equipment
must
know
and
follow
all
applicable
codes
and
occupational
safety
practices
as
well
as
the
precautions
on
these
labels.
WARNING
Do
Not
Remove,
Destroy,
Or
Cover
This
Label.
ELECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
servicing.
Keep
all
panels
and
covers
securely
in
~
INDUCTION
HEATING
can
cause
injury
or
burns.
Do
not
touch
or
handle
induction
head
during
operation.
Keep
metal
~eweiry
and
Other
metal
personal
Items
away
from
head
during
operation.
Allow
cooling
period
before
handling
parts.
INDUCTION
HEATING
can
be
hazardous.
Read
and
follow
this
label
and
the
Owners
Manual
carefully.
Only
qualified
persons
are
to
Install,
operate,
or
service
this
unit
according
to
all
applicable
codes
and
safety
practices.
Keep
children
away.
INDUCTION
HEATING
can
cause
fire.
Do
not
overheat
parts
and
adhesive.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Properly
ventilate
work
area.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
Instructions
for
material
used.
Figure
1.
Power
Source
Label
Figure
2.
Induction
Head
Label
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
DIsconnect
Input
power
before
main
taining
or
servicing.
Keep
all
covers,
guards,
and
panels
securely
In
place.
Figure
3.
Controller
Label
Keep
all
labels
readable.
If
any
label
is
unreadable
or
damaged,
order
replacements
free
of
charge
by
calling
414-735-4356.
Read
NFPA
Standard
70,
NatIonal
Electrical
Code,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269
and
CSA
Standard
C22.1,
Canadian
Electrical
Code
Part
1,
from
Canadian
Standards
Association,
Standards
Sales,
17$
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
7\
a
AVERTISSEMENT
I
CHAFFAUGEPARINDUCTIONpeutetrehasar.
deux.
Lire
Ia
manuel
dlnstructions
avant
utillsation.
No
poe
Installer
cur
une
surface
combustible.
S.147
876
UN
CHOC
ELECTRIQUE
peut
etre
mortel.
Installation
et
raccordement
de
cette
machine
dolventetreconformesatouslescodespertlnents.
a
WARNING
INDUCTION
HEATING
can
cause
injury
or
burns.
Do
not
touch
or
handle
Induction
head
during
operatIon.
Keep
metal
leweiry
and
other
metal
personal
Items
away
from
head
during
operation.
Allow
coolIng
period
before
handling
parts.
9.147
818
SR9_7191
TABLE
OF
CONTENTS
SECTION
1
SAFETY
SIGNAL
WORDS
1
SECTION
2
SPECIFICATIONS
1
SECTION
3
INSTALLATION.
3-1.
Installing
Induction
Head
2
3-2.
Installing
Transformer
3
3-3.
Connecting
Coolant
Supply
4
3-4.
Remote
Control
Connections
4
3-5.
Connecting
Input
Power
5
SECTION
4OPERATION
7
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
9
5-2.
Overload
Protection
10
5-3.
Troubleshooting
10
SECTION
6
ELECTRICAL
DIAGRAMS
11
SECTION
7
PARTS
LIST
Figure
7-1.
Complete
Assembly
14
Figure
7-2.
Transformer
&
IC
Induction
Head
17
OM-i48
109-
2/92
SECTION
1
SAFETY
SIGNAL
WORDS
i~Od1
I
9~9
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
a
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
inlury
or
loss
of
life.
a
CAUTION
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
~
IMPORTANT:
statements
identi&
special
instructions
necessary
for
the
most
efficient
operation
of
this
equipment.
SECTION
2
SPECIFICATIONS
3
4
1
Power
Source
2
Transformer
3
Head
4
Heating
Surface
2
Figure
2-1.
Induction
Heating
System
S1~15I
874
OM~148
109
Page
1
3-2.
Installing
Transformer
A.
Transformer
Dimensions
Inches
Millimeters
A
9.3/4
248
8
7-12
191
C
2-7/8
73
0
4-3/8
111
E
6
152
Figure
3-2.
Transformer
Overall
Dimensions
And
Mounting
Hole
Layout
B.
Connecting
Transformer
To
Power
Source
~r---~
=
0
Or
Figure
3-3.
Transformer
Connections
To
Power
Source
E
I
I
Ret.
SA.147
261
1
2
3
1
Transformer
2
lOft.
(3m)
Interconnecting
Cord
3
Plug
4
Keyway
5
Rear
Panel
Of
Power
Source
6
4-Socket
Receptacle
RC8
To
connect
pug
to
receptacle,
align
keyway,
insert
plug,
and
tighten
4
threaded
collar.
LJ
ST-ISO
151-A
OM-148
109
Page
3
3-3.
Connecting
Coolant
Supply
a
WARNING
OVERHEATING
can
damage
induction
head.
If
using
recirculating
coolant
system,
do
not
make
connections
from
coolant
system
to
water
valve;
instead
make
connections
directly
from
coolant
system
to
induction
head
hoses.
INCORRECT
COOLANT
FLOWRATE
can
damage
coolant
system
and
head.
Maintain
I
qt/min
(1
Lmiri)
coolant
flowrate
at
all
times.
Figure
3-4.
Connections
To
Coolant
Supply
Tools
Needed:
2
I
Coolant
Supply
Obtain
and
install
coolant
supply.
2
Induction
Head
Coolant
Pipe
ST-150
755
Install
hose
ends
onto
either
pipe
on
head.
Secure
with
clamps.
3
Hose
Clamp
Obtain
hose
clamps.
4
Coolant
Hose,
1/4
in.
(6
mm)
Inside
Diameter
Obtain
hoses
long
enough
to
connect
head
to
coolant
supply.
5
Fittings
Install
proper
fittings
onto
hoses.
Connect
hoses
to
cool
ant
supply
fittings.
6
Coolant
Supply
Fittings
I
qtimin
(1
Ljmin)
coolant
flow
rate
required.
3-4.
Remote
Control
Connections
S
4
I
Plug
2
Threaded
Collar
3
Keyway
4
9-Socket
Receptacle
RC9
5
Rear
Panel
Of
Power
Source
To
connect
to
receptacle,
align
key.
ways,
insert
plug,
and
tighten
threaded
collar.
Socket
lnformat~on:
1
+15
volts
dc
output
with
respect
to
circuit
common.
2
Contact
closure
between
sockets
1
and
2
energizes
power
source.
3
0
to
+10
volts
dc
signal
for
power
source
frequency
control.
4
Circuit
common.
5
0
to
+10
volts
dc
signal
for
power
source
output
control.
6
0
to
+15
volts
dc
signals
power
source
failure
to
remote
control
device.
7
Circuit
common.
8
Not
used.
9
+
10
volts
dc
output
with
respect
to
circuit
common.
Ref.
5.0645/
Ref.
5.0628
/
Ref.
ST.
150
751-A
Figure
3-5.
9-Socket
Receptacle
Connections
3-5.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
A.
Positioning
Jumper
Links
a
WARNING
ELECTRIC
SHOCK
HAZARD.
Read
safety
information
at
beginning
of
Section
3-5
be
fore
proceeding.
swarn31
10191
Turn
OFF
unit
POWER
Switch.
Jumper
links
allow
operation
on
dif
ferent
input
voltages
and
are
facto
ry
set
for
the
highest
input
voltage.
Check
input
voltage
available
at
site.
230
460
230
d
~d~~6
APPLIES
TO
80TH
1E2
AND
TE3
S-ISO
944
1
Terminal
Strip
TE2
2
Terminal
Strip
TE3
3
Input
Voltage
Jumper
Link
4
Input
Voltage
Label
Look
at
jumper
links
and
compare
link
position
with
label.
Move
links
to
match
input
voltage.
For
example,
use
230
volts
posi
tion
on
label
when
230
volts
input
power
is
available.
Reinstall
and
secure
wrapper.
Tools
Needed:
Figure
3-6.
Input
Voltage
Jumper
Links
Location
Ret
ST-ISO
781
OM-148
109
Page
5
B.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
HAZARD.
Read
safety
information
at
beginning
of
Section
3-5
be.
fore
proceeding.
Turn
OFF
unit
POWER
switch.
1
Input
Conductors
Select
size
and
length
using
Table
3-1.
2
Three-Phase
Line
Disconnect
Switch
Obtain
and
install
switch.
3
Grounding
Conductor
Select
size
and
length
using
Table
3-1.
Be
sure
ground
conduc
tor
goes
to
an
earth
ground.
4
Input
Terminal
Block
5
Ground
Terminal
Connect
input
conductors
to
termi
nal
block
and
grounding
conductor
to
ground
terminal
in
power
source.
Connect
input
conductors
and
grounding
Conductor
to
deener
gized
line
disconnect
switch.
6
Line
Fuses
Select
fuses
or
circuit
breakers
us
ing
Table
3.1.
Install
into
deener
gized
line
disconnect
switch.
Connect
deenergized
supply
con
ductors
to
line
disconnect
switch.
Place
line
disconnect
switch
in
ON
position
before
using
power
source.
ST-15O76~
Table
3-1.
Electrical
Service
Requirements
Input
Voltage
230
460
input
Amperes
At
Rated
Output
18
9
Circuit
Breaker
Size
Range
In
Amperes
36
Fuse
Size
In
Amperes2
25
15
Input
Conductor
Size
In
AWG/Kcmll3
12
14
Maximum
Input
Conductor
Length
in
Feet
(Meters)4
138
(42)
359
(110)
Grounding
Conductor
Size
In
AWG/KcmiI5
12
14
*
These
values
are
calculated
from
the
1990
edition
of
the
National
Electrical
Code
(NEC).
Circuit
breaker
range
is
150%
to
not
more
than
200%
of
rated
input
amperage
of
the
welding
power
source
(Article
630-12(a)
of
NEC).
2
Standard
fuse
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source
(Article
630-126
of
NEC).
~
Input
conductor
size
is
for
insulated
copper
wire
with
75C
rating
with
not
more
than
three
single
current
carrying
conductors
in
a
cable
or
raceway
(Article
630-16
of
NEC).
~
Maximum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
termi
nals
of
the
welding
power
source
(Articles
210-19(a)
and
215-2(b)
of
NEC).
~
The
grounding
conductor
shall
be
colored
or
identified
as
specified
In
the
NEC.
Grounding
conductor
size
for
copper
wire
is
not
required
to
be
larger
than
input
conductor
(Article
250-95
of
NEC).
~
6
Figure
3-7.
Input
Power
Connections
OM-148
10
~qe
6
SECTION
4-
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
servicing.
Keep
all
panels
and
covers
securely
in
place.
INDUCTION
HEATING
can
cause
injury
or
burns.
Do
not
touch
or
handle
induction
head
during
operation.
Keep
metal
jewelry
and
other
metal
personal
items
away
from
head
during
operation.
Allow
cooling
period
before
handling
parts.
INDUCTION
HEATING
can
cause
fire.
Do
not
overheat
parts
and
adhesive.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Properly
ventilate
work
area.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
1
Power
Adjustment
Control
2
Frequency
Adjustment
Control
3
Remote
Power/Frequency
Adjustment
Switch
4
Power
Switch
Ref.
ST.f
51
574
Figure
4-1.
Controls
1
2
~
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
Wear
dry
insulating
gloves
and
safety
glasses
with
side
shields.
sb3.1
tO/91
Figure
4-2.
Safety
Equipment
Ret
ST.147
386.A
1
Power
Adjustment
Control
Use
control
to
select
power
be
tween
the
minimum
and
maximum
output
of
the
power
source.
The
numbers
around
the
control
are
for
reference
only.
Figure
4-3.
Power
Adjustment
Control
OM-148
109
Page
7
Figure
4-6.
Coolant
Supply
1
Frequency
Adjustment
Con
trol
Use
control
to
select
frequency
output
between
25
and
50
kilo
hertz.
To
obtain
maximum
heat
out
put,
select
frequency
that
matches
rating
of
induction
head.
Figure
4-4.
Frequency
Adjustment
Control
I
Remote
Power/Frequency
Adjustment
Switch
Use
switch
to
select
way
of
con
trolling
unit
Output.
For
front
panel
control,
place
switch
in
PANEL
position.
For
remote
control,
place
switch
in
the
REMOTE
9
position.
Figure
4-5.
Remote
Power/Frequency
Control
Switch
eQe~
I
Coolant
Supply
Turn
on
coolant
supply
before
heating.
Turn
off
coolant
supply
when
fin
ished
heating.
Ref.
ST.150
755
OM-148
109
Pa~:e
8
I
Power
Switch
2
Figure
4-7.
Power
Switch
Use
switch
to
turn
unit,
fan
motor,
and
pilot
light
ON
and
OFF.
Unit
is
ready
to
heat
10
seconds
af
ter
POWER
Switch
is
placed
in
the
ON
position.
2
Pilot
Light
Figure
4-8.
Sequence
Of
Induction
Heating
Process
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
servicing.
Keep
all
panels
and
covers
securely
in
place.
INDUCTION
HEATING
can
cause
injury
or
burns.
Do
not
touch
or
handle
induction
head
during
operation.
Keep
metal
jewelry
and
other
metal
personal
items
away
from
head
during
operation.
Allow
cooling
period
before
handling
parts
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons
only.
5-1.
Routine
Maintenance
Table
5-1.
Maintenance
Schedule
Time
Maintenance
Before
each
use.
Clean
copper
surfaces
between
transformer
and
head.
Every
month.
Above
normal
equipment
use:
Check
all
labels
(see
6
month
entry),
repair
any
damaged
insulation
or
replace
cable,
repair
any
breaks
or
clogs
in
coolant
hoses,
clean
internal
parts
(see
6
month
entry),
clean
and
tighten
connections.
Every
3
months.
Repair
any
damaged
insulation
or
replace
cable,
and
repair
any
breaks
or
clogs
in
coolant
hoses.
Clean
and
tighten
connections.
Every
6
months.
Replace
any
labels
that
are
unreadable
or
damaged
(see
Section
7
for
part
number).
Blow
out
or
vacuum
dust
and
dirt
from
inside
using
a
clean,
dry
air-
stream
or
vacuum
suction.
Install
&
Conn~
\
Put
On
Turn
On
~)
)
Set
Position
~
Near
Head
Personal
Safety
Coolant
Supply
Controls
I
Induction
Heating
,
Equipment
)
Equipment
_________________
_________________
Heating
Surface}
Swit
10
Seconds
To
Heat
)
)
Wait
~
)
Unit
Ready
OM.148
109
Page
9
S
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.
5-3.
Troubleshooting
a
WARNING
5-2.
Overload
Protection
a
WARNING
ELECTRIC
SHOCK
AND
INDUCTION
HEATING
HAZARDS.
Read
safety
information
at
beginning
of
Section
5
before
proceeding.
ELECTRIC
SHOCK
AND
INDUCTION
HEATING
HAZARDS.
Read
safety
information
at
beginning
of
Section
5
before
proceeding.
Table
5-2.
Troubleshooting
Trouble
Remedy
Section
No
heat
output.
Replace
building
line
fuse
or
reset
circuit
breaker.
Secure
transformer
plug
in
power
source
receptacle.
Check
and
replace
POWER
switch
Si
if
necessary.
3-5
3-2
No
heat
output;
fan
motor
con-
tinues
to
run.
Thermostat
TPI
open
(overheating).
Allow
fan
to
run;
the
ther-
mostat
will
close
when
the
unit
has
cooled.
5-2
Low
heat
output.
Connect
power
source
to
proper
input
voltage
or
check
for
low
line
voltage.
3-5
SECTION
6-
ELECTRICAL
DIAGRAMS
PC
I
/PLG
I
5C2/Pt.02
PC3/PLG3
RC4/PLG4
RC5/PLGS
5C6/PLG6
5C7/PLG7
Figure
6-1.
CircuIt
Diagram
For
induction
Heating
Power
Source
p
SI
230/
460
509
I
2
PCG
CR
//
<
506-5
12
~
501-2
505-5
PCI
/2
505-2:
505-I
PC
1-6
4
~
PCI-I
6
~
~
501-9
7>
<<
PCI-C
9
>
901-10
504-9:
504-7
504-6
PC
1-14
9C4-2:
904-I
504-4
PCI-Il
502-2
PCI
-13
3_
0~
PEp~rE
507-2
907-3
P02-I
PCI
-
I
2
P03-I
PCY-
I
PC,-
SC.145
4340
OM-148
109
Page
11
a
28(RCe-6)
PED(P1137-4
W
z
W
I~3
tg
-~~
~
~
C2
4C3
Ad
Figure
6-2.
Wiring
Diagram
For
Induction
Heating
Power
Source
GND
TE
8A(SI
-601)
74(SI
-MID)
64(Sl
-TOP)
L3~
L2fifi
LI~S
I7AITP
I-TOP)
~OILI~OIL2~
TE3
230
460
230
TE2
230
460 230
1
14
WI
~I__
LI~I.~c1~j
UI UI
U
UI
~
_____
~
~
PM
I
0 0
264)Pt.GI-9
RC9
I
42C(Pt.GI
-6)
~o~oJ
&26(P(..GI-I)
39A(S2
6)
tj
-6
BACK
~~~42A(P1GI-2
CASE
4~(I4AT
SIM(
GPO
G~D
(TI
COIL
2-2)
24(S)
T~
ASICI
CflTTI
(
I
74)609-2
DC
~5A
PEO)PLG5-Ii)~3
I
I
03
I
W1IITE
L
-~
2)003
I
TI
-~OOI
-
05
PC3
T2
06
-Co
56*
-/
AS4RED~T2
-
LGS-6)
I
04
I
L
~
WHITE
04
p~15)
536(C)
~OB4
DC
___
TI
(
I
-2)~
~
ZI
(COIL
2-2)
0
IFC2
ZI
(COIL
PC2
I~I
SI
2QA
I
R4-LF
FT
I
.
ui.iT
(
___________
_________
~.
Io~o~ioi-o
_________
jj:J
~!1
WWT(PIG4-4
_________
RZO)PtG4-I(
________
W#IflPIG4-2)
___________
TI
(COIL
2-4)
EAT
420(GPO
OSI~1~
GPO
D5
I
LI
--
I
I
L
J
L
I
I
I I
I
I
121
*4T)P1135-6)
02
I
RED
(
I
\
CT2
I
PC4
~
C~42
RC8
28
(PC~-T
I)
I4A)Pt~G
I-IA
27)604)
AIA(TPI
-901)
AC)
p
AC21
TI(COIL
-4)
-
0WHT)P1135-I
r
-
091
I
I
RED
L
ASIO
9l~
2
30A)66-RIGHT
~_5O8)C2)061
D8J
~TE,
INST~L
C12
WITh
9EGI~4IPG
F*CIPG
603
-J
i~
__
-
~--~
rIffl~4I
604i
___________
P104
PC5/p~IUl~
REO)06-E2)
j
I
__________
W(4T(06-132)
J~J
P1G5liI~IiUi~i~i
WI4T)06-GI
~ci
L~J
~
RED)06-E?
I
607/
PE~P~-TI
P1137
W~.IT(PC4
~1~J
~i
WHT
)CT2)
602/
P102
24A(SPIICE
EL)
32A(62-CCW)
~LS.IcZ
TEL)
~
711
_________
~I~I
~
IOA(CPI-A
Pd
II3c1~
WHTccTI)
r1pc3
RC6/
P101
________
WWTICTI
I
~P1G3
TFb136
OM-148
109
Page
12
0
0
(0
0
w
(0
0
C.)
U)
a
a
CD
0
9
0
Replace
Coils
At
Factory
Or
Factory
Authorized
Service
Station
Description
Quantity
Figure
7-1.
Complete
Assembly
Item
Dia.
No.
Mkgs.
Part
No.
1
141
690
..
GROMMET,
scr
No.
8/10
panel
hole
.281sq
.197
high
4
.
.
2
.
.
..
PCi
..
.
150900
..
CIRCUIT
CARD,
control
1
PLG1
..
.
131
056
..
HOUSING
RECEPTACLE
&
SOCKETS,
(consisting
of)
1
113
746
. .
.
.
TERMINAL,
female
iskt
24-18
wire
14
PLG2
.
.
.
115
092
. .
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
1
113
746
.
.
.
.
TERMINAL,
female
iskt
24-18
wire
8
PLG3
..
.
131
054
..
HOUSING
RECEPTACLE
&
SOCKETS,
(consisting
of)
1
113746
.
.
.
.
TERMINAL,
female
lskt24-l8wire
2
PLG4
.
.
.
115
091
..
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
I
113746
.
.
.
.
TERMINAL,
female
lskt24-l8wire
10
PLG5
.
.
.
130
203
..
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
113
746
.
. .
.
TERMINAL,
female
lskt
24-18
wire
12
PLG6
.
.
.
115093
..
HOUSING PLUG
&
SOCKETS,
(consisting
of)
113
746
.
.
.
.
TERMINAL,
female
lskt
24-18
wire
6
PLG7
..
.
115
094
..
HOUSING PLUG
&
SOCKETS,
(consisting
of)
1
113
746
.
.
.
.
TERMINAL,
female
lskt
24-18
wire
4
..
3
147
507
..
INSULATION,
PC
card
1
..
4
.
.
.
TE2,3
.
.
.
038
081
..
601
219
..
145
453
..
BLOCK,
term
20A
4P
LINK,
jumper
term
blk
20A
BRACKET,
mtg
PC
board
2
4
1
133
405
.
.
NUT,
speed
10-24
rectangular
4
7
.
.
..
PC4
.
.
.
146
955
..
CIRCUIT
CARD,
capacitors
I
8
151
022
..
INSULATION,
PC
card
1
9
098
691
..
STAND-OFF,
No.
6-32
x
.500
Ig
.25Ohex
4
10
.
.
..
RC8
.
.
.
148
118
..
RECEPTACLE,
twlk
flange
mtg
4skt
1
11
.. ..
RC9
. .
.
147
820
..
HOUSING
RECEPTACLE
&
SOCKETS,
(consisting
of)
1
079
534
..
. .
TERMINAL,
female
iskt
18-14
wire
9
12
.
.
..
CT2
.
.
149
256
..
TRANSFORMER,
current
1
13
126
026
..
LABEL,
warning
electric
shock
can
kill
3
14
+151
011
..
WRAPPER,
w/insulation
(consisting
of)
1
15
151
010
.
.
.
.
STRIP,
ppr
100%
rag
.020
x
4.500
x
10.000
1
16
128415..
CLAMP,saddle
1
17
126
416
..
HANDLE,
molded
I
..
18
147
876
..
LABEL,
warning
general
precautionary
I
..
19.
.
..
PC2
.
.
.
144
483
..
CIRCUIT
CARD,
interconnecting
1
20
.
.
..
CT1
..
.
150
925
..
TRANSFORMER,
current
1
21
094 517
..
SCREW,
mach
brs
trh
10-32
x
.500
4
22
. .
..
PC3
.
.
.
146
951
..
CIRCUIT
CARD,
bus
connect
1
23
.
.
.
Q5,6
.
.
.
132
843
..
TRANSISTOR,
IGBT
module
75A
600V
2
24
.
.
..
TPI
.
.
.
032
810..
THERMOSTAT,
NC
1
25
.
.
.
VR1-3.
.
.
090
304
..
VARISTOR,
220
joule
73OVDC
3
26
.
.
..
SRI
.
.
.
131
828
..
RECTIFIER,
integ
100A
1200V
1
27
128
803
..
BAR,
support
heat
sink
top
1
28
145
689
..
HEAT
SINK,
power
module
1
29
119
757
..
BAR,
support
heat
sink
bottom
1
30
148
828
..
BRACKET,
mtg
tan
motor
1
31
.
.
..
FM
.
.
.
.
146932
..
MOTOR,
fan
1
32
000
366
..
RING,
retainer
E
.250
shaft
grv
x
.O2Sthk
2
33
132
951
..
BLADE,
6.5
in
6wg
.250
bore
CW
1
34
.
.
.
Q1-4
.
.
.
131
467
..
TRANSISTOR,
mosfet
45A
500V
4
35
.
.
.
05,8,9
.
.
147
947
..
DIODE,
fast
recovery
30A
800V
3
010
913
..
WASHER,
flat
brs
.218
ID
x
.46000
x
.O3lthk
10
601
835
.
.
NUT,
brs
hex
10-32
6
36
.
.
..
TEl
..
.
147
386
..
BLOCK,
term
70A 3P
1
.
.
37
145
692
..
CASE
SECTION,
front/bottom/rear
1
. .
38
.
.
..
Zi
...
.
146
946
..
STABILIZER
1
OM-148
109
Page
15
Part
No.
Figure
7-1.
Complete
Assembly
(Continued)
39
40
42
.43....
R5....
44....R3,4
.45....
R6....
..46....CR1...
47
48
..49.,..PL1....
.
51
52
53
54....C1,2
55....R1,2
57
146976
146975
146974
141
422
141
424
139203
144656
106462
019663
149338
097922
006
426
136190
124696
073
562
091
441
099
037
I
1
1
1
1
2
1
1
4
1
1
1
2
2
4
.2
ift
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
No.
-
Mkgs.
Description
Quantity
TRANSFORMER,
pwr
main
325V
(consisting
of)
COIL,
pri/sec
325V
RH
COIL,
pri/sec
325V
LH
INSULATOR,
flat
pack
RESISTOR,
WW
fxd
30W
25
ohm
RESISTOR,
WW
fxd
30W
8K
ohm
RESISTOR,
WW
fxd
30W
20K
ohm
RELAY,
end
24VDC
DPDT
MOUNT,
nprn
15/16
OD
x
3/8rec
3/16
x
3/8
NAMEPLATE,
(order
by
model
and
serial
number)
LIGHT,
md
red
lens
28V
SWITCH,
rocker
DPDT
4A
25OVAC
KNOB,
pointer
.875dia
x
.250
ID
CLAMP,
capacitor
NUT,
speed
U
type
10-32
CAPACITOR,
elctlt
1
700uf
400VDC
POTENTIOMETER,
C
sltd
sit
l/T
2W
10K
ohm
SWITCH,
tgl
3PST
40A
600V
EDGE
TRIM,
style
62-1/16
black
w/clips
(order
by
ft)
OM-148
109
Page
16
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Miller IH XFMR4 Owner's manual

Miller
Brand
Miller
Model
IH XFMR4
Category
Welding System
Type
Owner's manual
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