Miller IHPS II 5 KW Owner's manual

Miller
Brand
Miller
Model
IHPS II 5 KW
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
April
1995
Form:
OM-171
006
Effec
tive
With
Serial
No.
KF869436
OWNERS
MANUAL
c~
~'
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
U
Give
this
manual
to
the
operator.
~
Have
only
trained
and
qualified
persons~
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
noLunderstand
the
directions.
11113
For
help,
call
your
distributor
-.
-.
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
IHPS
115
KW
Induction
Heating
Power
Source
10
To
50
kHz
Induction
Heating
Output
5
kW
Output
At
100%
Duty
Cycle
Uses 230
Or
460
Volts,
50/60
Hz,
Three-Phase
Input
Power
Overheating
And
Automatic
Shutdown
Protection
14-Socket
Remote
Control
Receptacle
cover
5/94
-
ST-801
046
'
1995
MILLER
Electric
Mtg.
Go.
PRINTED
IN
USA
I
I
J
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
esctusive
with
no
othar
guarantees
or
warrantias
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
lerms
and
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
oflginal
ratail
purchasar
that
new
MILLER
equipment
sold
ahar
the
effective
date
of
this
limited
warranty
is
tree
of
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OThER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
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
detect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
lobe
followed.
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
thst
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
eher
the
equipment
is
sent
to
s
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
an
International
distributor.
1.
5YesrsParts3YearsLabor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
TranstormerlReclifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
lYearPsrlaandLabor
Motor
Driven
Guns
*
Process
Controllers
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
*
Load
Banks
SDX
Transformera
Running
Gear/Trailers
Plasma
Cutsng
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
True
BIueTM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
s
minimum
of
one
yesr
whichever
is
greeter.)
5.
6
Months
Batteries
N
6.
9ODaysPsrtssndLabor
MIG
Guns/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
*
Accessory
Kits
Replacement
Parts
MILLERS
True
BIueTM
Umited
Warranty
shell
nor
epply
to:
1.
Items
fumished
by
MILLER.
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufecturers
warranty,
if
any.
2.
Consumable
components:
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
parts
that
fsil
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improgerfy
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.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIALJINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace-
mental
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
espense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
F.O.B.
sls
MILLER
suthorized
ser
vice
facility
as
determined
by
MILLER.
Theretore
no
compenaslion
or
reimburse
ment
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
CONSEDUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OThER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
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,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
stales
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
spe
cific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
state
to
stale.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
then
ss
staled
herein,
snd
to
the
extent
that
they
may
not
be
waived,
the
limitations
end
exclusions
set
out
above
may
nol
apply.
This
Limited
Warranty
provides
specific
legal
flghts,
end
other
rights
msy
be
available,
but
may
vary
from
province
to
pmvince.
.1
r
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
sh)pment.
File
any
Claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
tiling
or
settling
claims
may
be
obtained
trom
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
miller
4/95
INDUCTION
HEATING
SAFETY
PRECAUTIONS
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
tire.
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
(MSDS5)
and
manufacturers
instructions
for
material
used.
Figure
1.
Power
Source
Label
4~
WARNING
INDUCTION
HEATJNG
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.
S-147
878-A
Figure
2.
Induction
Head
Label
Figure
4.
Controller
Label
Figure
3.
IHPS
Rack
Below
are
examples
of
the
precautionary
labels
found
Keep
all
I
abels
readable.
If
any
label
is
unreadable
on
the
power
source,
the
controller,
and
the
head
damaged,
order
replacements
free
of
charge
by
calling
assembly.
Any
person
who
installs,
operates,
main-
414-735-4356.
tains,
or
services
this
equipment
must
know
and
follow
all
applicable
codes
and
occupational
safety
practices
as
well
as
the
precautions
on
these
labels.
a
\IVA
R
ru
i
IJ
~
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.
Do
Not
Remove,
Destroy,
Or
Cover
This
Label.
A
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,
178
Rexdale
Bouk
hfard,
Rexdale,
Ontario,
Canada
M9W
1R3.
a
AVERTISSEMENT
I
CHAFFAUGE
PAR
INDUCTION
peut
etre
hasardeux.
Lire
le
manuel
dinstructions
avant
utilisation.
Ne
pas
installer
sur
une
surface
combustible.
S-147 876-A
7s~
UN
CHOC
ELECTRIQUE
peut
etre
mortel.
Installation
et
raccordement
de
cette
ma-
chine
doivent
etre
conformes
a
tous
les
codes
pertinents.
WARNING
ELECTRIC
SHOCK
can
kill.
~
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
remov
ing
cover
plate
for
voltage
connec
tions.
Do
not
operate
this
power
source
with
cover
plate
open
or
missing.
Be
sure
cover
plate
is
in
place
and
secure
betore
oper
ating
unit.
S-166
409
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
maintaining
or
servicing.
Keep~aIl
covers,
guards,
and
panels
securely
in
place.
S-137
260-A
SR8_3195
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
SECTION
3
INSTALLATION
2
3-1.
Connecting
Head/Coil
To
Power
Source
3-2.
Remote
14
Receptacle
RC14
Information
And
Connections
3-3.
Connecting
Input
Power
3
SECTION
4OPERATION
5
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
6
5-1.
Routine
Maintenance
5-2.
Overload
Protection
5-3.
Safety
Interlock
Switch
And
Measuring
Tuning
Capacitor
Voltage
5-4.
Measuring
Input
Capacitor
Voltage
5-5.
Troubleshooting
SECTION
6
ELECTRICAL
DIAGRAMS
9
SECTION
7
PARTS
LIST
12
Figure
7-1.
Complete
Assembly
12
NOTE
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Backg
round
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
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
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modi
0.1
4/93
2
2
6
7
7
7
8
OM~171
006-4/95
SECTION
1
-
SAFETY
INFORMATION
.
modl.1
2/93
A~
CAUTION
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Induction
Heating
Power
Source
U
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
1
Safety
Alert
Symbol
2
Signal
Word
1
2
2
WARNING
means
possible
death
or
serious
injury
can
happen.
3
CAUTION
means
possible
minor
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts.
happen.
ELECTRIC
SHOCK
can
kIII.~
MOVING
PARTS
can
injure,
injury
or
equipment
damage
can
Disconnect
input
power
betorejj_
~
Keep
all
panels
and
covers
closed
3
Statement
Of
Hazard
And
installing
or
servicing.
when
operating.
Result
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
6~Y1~~~
~
READ
SAFETY
BLOCKS
at
start
of
I
Read
safety
blocks
for
each
sym
Section
3-1
before
proceeding.
I
b~I
shown.
7
NOTE
7H
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
Specification
Description
Output
Frequency
Rated
Output
Required
Reflective
Inductance
Type
Of
Input
Power
Input
Amperes
At
Rated
Output
Input
Amperes
While
Idling
KVA/KW
Used
At
Rated
Output
KVNKW
Used
While
Idling
Overall
Dimensions
Weight
10
To
50 kHz
5
kW
At
100%
Duty
Cycle
Max
210
Amperes
(RMS),
310
Volts
(RMS)
5
to
30
j.th
Three-Phase,
230
Or
460
Volts
AC,
50/60
Hz
20.5AAt23OV;
10.5AAt46OV
0.6
A
At
230
V;
0.3
A
At
460
V
8.5
kVAI6.3
kW
0.15kVA/0.146kW
Length:
19-1/2
in
(495
mm);
Width:
11-1/2
in
(292
mm);
Height:
11-3/4
in
(298
mm)
Net:
54
lb
(24.5kg);
Ship:
58
lb
(26.3
kg)
OM-171
006
Page
1
SECTION
3-
INSTALLATION
3-1.
Connecting
Head/Coil
To
Power
Source
Figure
3-1.
Connecting
Head/Coil
To
Power
Source
Rear
Panel
1
1
Output
Receptacle
RC15
2
Piug
From
Head/Coil
3
Threaded
Coflar
Receptacle
RC15
is
a
4-socket
receptacle.
To
connect
to
receptacle,
align
key-
way,
insert
plug,
and
tighten
threaded
collar.
2
Socket
Information:
A,
C
Approx.
350
volts
ac,
high-frequency
output
B,
D
Approx.
350
volts
ac,
high-frequency
output
10
to
50
kHz
RMS
10
to
50
kHz
RMS
3-2.
Remote
14
Receptacle
RC14
Information
And
Connections
5T-801
049
1
Plug
2
Threaded
Collar
3
Keyway
4
Remote
14
Receptacle
RC14
(See
Table
3-1)
To
connect
to
receptacle,
align
key
,way,
insert
plug,
and
tighten
threaded
collar.
sb7.1
3/93
-
Ref.
S-0004-A/
Ref.
s-o7so;Ref.
ST-801
049
Figure
3-2.
Remote
14
Connections
OM-171
006
Page
2
Table
3-1.
Remote
14
Socket
Information
REMOTE
14
Socket*
Socket
Information
Remote
Contactor
A
B
+24
volts
dc.
Contact
closure
to
A
completes
24
volts
dc
contactor
control
circuit.
Remote
Output
Control
C
D
E
G
Command
reference;
+10
volts
dc.
Control
circuit
common.
Input
command
signal
(potentiometer
wiper
or
0
to+10
volts
dc).
24
volts
dc.
Power
Source
Fault
F,
J
Absence
of
internal
contact
closure
between
F
and
J
signals
power
source
failure
to
remote
control
device.
Remote
Metering
H
I
L
M
N
K
Coil
loss
compensation
value.
Actual
frequency
output
signal
(1
voltI5
kHz)
Average
power
output
signal
(1
volt/i
kW)
Voltage
output
signal
RMS
(1
volt/50
volts)
Current
output
signal
RMS
(1
volt/50
amperes)
Chassis
common.
3-3.
Connecting
Input
Power
a
WARNING
Tobls
Needed:
-:~
c:II::::1===IJ
5/16
in
Figure
3-3.
Input
Voltage
Jumper
Links
Location
E
LECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.
Turn
Oft
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.
swam3.r
2/93
A.
Positioning
Jumper
Links
3
,
Turn
Oft
unit
Power
switch.
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
Terminal
Strip
TE2
2
Input
Voltage
Jumper
Link
3
Input
Voltage
Label
Four
jumper
links
supplied.
Look
at
jumper
links
and
compare
link
po
sition
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
wrapper
or
go
on
to
Figure
3-4.
Ref.
ST-Sal
050
OM-i71
006
Page
3
B.
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
Input
Conductors
3
Grounding
Conductor
Select
size
and
length
using
Table
3-2.
Conductor
rating
must
comply
with
national,
state,
and
lo
cal
electrical
codes.
4
Strain
Relief
Connector
Insert
conductors
through
strain
relief.
5
Input
Terminal
Block
6
Power
Source
Ground
Terminal
Connect
grounding
conductor
to
ground
terminal
first.
Then
connect
input
conductors
to
terminal
block.
7
Disconnect
Device
Ground
Terminal
Install
and
connect
grounding
conductor
and
input
conductors
in
conduit
or
equivalent
to
deener
gized
line
disconnect
device.
Connect
grounding
conductor
first,
then
line
input
conductors.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
Reinstall
wrapper.
8
Overcurrent
Protection
Select
type
and
size
using
Table
3-2.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
ST-801
050
Figure
3-4.
Input
Power
Connections
Table
3-2.
Electrical
Service
Guide
Input
Voltage
230
460
.
Input
Amperes
At
Rated
Output
20.5
10.5
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
30
15
Mm
Input
Conductor
Size
In
AWGIKcmiI
10
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
.
174(53)
276(84)
.
Mm
GroundIng
Conductor
Size
In
AWG/Kcmil
10
14
Reference:
1993
National
Electrical
Code
(NEC).
5.0092J
7
8
Tools
Needed;
cT~:IT~::z:J===:~lJ
5/16
in
OM-171
006
Page
4
SECTION
4-
OPERATION
ELECTRIC
SHOCK
can
kill.
Do
not
touch
hve
electrical
parts.
Disconnect
input
power
before
servicing.
Keep
all
panels
and
covers
securely
in
place.
INDUCTION
HEATING
can
cause
fire.
Do
not
overheat
parts
and
adhesive.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
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.
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.
2
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
Wear
dry
insulating
gloves
and
safety
glasses
with
side
shields.
sb3.r
10/91
Figure
4-2.
Safety
Equipment
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
in
kilowatts
(kW).
POWER
ADJUST
Ref.
ST168
461-A
Adjustment
Control
1
Remote
Power
Control
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
Remote
14
position.
Connect
controller
or
pendant
control
to
Remote
14
receptacle
(see
Sec
tion
3.2).
Figure
4-4.
Remote
Power
Control
Switch
£~
WARNING
1
3
2
Power
Adjustment
Control
Switch
Power
Switch
Remote
Power
Adjustment
ST-sal
046
Figure
4-1.
Controls
OM-171
006
Page
5
1
Power
Switch
Figure
4-5.
Power
Switch
Figure
4-6.
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
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
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
MaintenanÆe
and
troubleshooting
to
be
performed
only
by
qualified
persons
only.
ION
2
~FF
POWER
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
On
position.
QOFF
2
Pilot
Light
Install
&
Connect))
Install
&
Connec~~~~
Install
&
Connect~~
~\
Put
On
Turn
On
)
Power
Source
Induction
Coolant
Supply,
)
)
Personal
Safety
)
)
Coolant
Supply,
________________
Head/Coj!~//
If
Required
J
,
Equipment
~
If
Required
~,J
)
Position
Work)
Turn
On~))
Wait
)
)
To
Heat
Unit
Ready
Near
Power
10
Seconds
Head/Coil
Switch
________________
5-1.
Routine
Maintenance
Turn
Off
all
power
before
maintaining.
Figure
5-1
-
Maintenance
Schedule
5T-801
046
OM-171
006
Page
6
Overload
Protection
I~/~
READ
SAFETY
BLOCKS
at start
of
Section
5
before
proceeding.
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.
B.
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
pow
er
ratio
limiting,
which
limits
the
output
power
based
on
improper
load
impedance.
5-3.
Safety
Interlock
Switch
And
Measuring
Tuning
Capacitor
Voltage
Figure
5-2.
Safety
Interlock
Switch
And
Measuring
Tuning
Capacitor
Voltage
Check
input
capacitor(s).
Measure
the
do
voltage
across
the
positive
(+)
and
negative
(.-)
termi
nals
every
30
seconds
until
voltage
is
near
0
(zero)
volts.
Proceed
with
job
inside
unit.
Reinstall
wrapper
when
finished.
ST-BOO
998
A.
Overheating
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
pre
vents
the
contactor
from
energizing
with
the
cover
open.
To
measure
capacitor
voltage,
turn
off
power
source
and
disconnect
input
power.
Open
tuning
capacitor
cover.
3
Tuning
Capacitor
Assembly
4
Voltmeter
Measure
voltage
across
busbars
every
30
seconds
until
voltage
is
near
0.(zero)
volts.
Proceed
with
job
near
tuning
capac
itor
assembly.
Close
and
secure
cover
when
finished.
Ref.
ST-801
049
Significant
DC
voltage
can
remain
on
capacitors
after
unit
is
Off.
Always
check
capacitors
as
shown
to
be
sure
they
have
discharged
before
working
on
unit.
~
5/16
in
5-4.
Measuring
Input
Capacitor
Voltage
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Turn
Off
power
source
and
discon
nect
input
power.
Remove
wrapper.
1
Input
Capacitor
Cl
2
Input
Capacitor
C2
3
Voltmeter
Significant
DC
voltage
can
remain
on
capaci
tors
after
unit
Is
Ott.
Always
check
ALL
capaci
tors
as
shown
to
be
sure
they
have
discharged
before
working
on
unit.
-
Tools
Needed:
Figure
5-3.
Measuring
Input
Capacitor
Voltage
cII~J===u
5/16
in
OM-171
006
Page
7
5-5.
Troubleshooting
READ
Sectio
SAFETY
n
5
betor
BLOCKS
at
start
of
e
proceeding.
Table
5-1.
Troubleshooting
Trouble
Remedy
-~
Replace
building
line
fuse
or
reset
circuit
breaker.
-~
Secure
headJcoil
plug
in
power
source
receptacle.
-~
Check
and
replace
Power
switch
it
necessary.
-~
Connect
power
source
to
proper
input
voltage
or
check
for
low
line
voltage.
-~
-~
Tuning
capacitor
cover
safety
interlock
switch
open.
-~
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermostat
will
-~
close
when
the
unit
has
cooled.
~-~
Check
tuning
of
induction
heating
output
system.
-.-~
Section
~
3-1
3-3
5-3
5-2
Table
5-2
No
heat
output.
i
No
heat
output;
fan
motor
con-
tinues
to
run.
I
Low
heat
output.
a
Table
5-2.
Tuning
Chart
4A
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
Decrease
matching
transformer
turns
ratio
and
add
capacitance
Low
High
-
Low
Lower
capacitance
Low
High
High
Increase
matching
transformer
tums
ratio,
or
lower
capacitance
and
increase
inductance
Low
High
Mid-Range
Increase
matching
transformer
turns
ratio
and
lower
capacitance
High
voltage
>
300V
rms;
Low
voltage
<200
V
rms;
Operating
current
range:
010210
A
rms
OM-171
006
Page
8
SECTION
6
-
ELECTRICAL
DIAGRAMS
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biagram
For
Induction
Heating
Power
Source
P13-I
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OM-171
006
Page
9
Figure
6-2.
Wiring
Dia~ram
For
Induction
Heating
Power
Source
TE
01
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,
38A~PLG~-7
C
~
~fi
26A)PLI2-12
48A)PLGI
-6)
40A(PLS2-9)
3
IA
(PLG2-3)
32A(PLG2-5)
L
~
42C(BA~
CASE
~
44A(PLG2-61
0~0
<0
841
S3-N0)
-
AC3
C2
~
W1-1T(VCM))
I
~
44(S)-BUT)
)
3C(TE2-4)
WHT(VCMI
(~\
2C(TE2-)
24(S)-TOP)
WHT(VCMI
56A(PC3-TOPI)
584
I
PC3-B0
28A(CT3
03.C4.C5)
42C(RC
14-K
42A(PLG)
-8)
42O(~AT
SINK
GND
0
–
AS)
L
-J
TI.
(T)-COILI-2)
(RED)
H
PC3
TOPIC
r-1
~
1D5
I
BOT2OI
r
1
~
06
I
BUT)
RC2
I)o~~
08
I
IND)
L__J
H]
H]
AC2*
AC)
AC2-
ACI
RED
IPLG3-7)
WHTIPLG3-6I
45A(CT2
CI.
C4
C5
I
574
(
55A(PC3-T~
9~
~.cU~7
1)
~-JI~C)
~
0
r
-i
02
02
A~2L
J
B2
RED
P
04-10
~IS21WHTIpLG4g(
RED(PLG4-))
05
11W
P
-
~WHT(PLG4-7)
P
4-
~Q6
SI
(WI)
WI)
044
BACK
CASE
(0
GND
CO
-
CA
I
o
0
I
A
A
A
0
.
A
I-
)
0
U
~T2
NOTE,
INSTALL
Cr3
WITH
ARROW
FACING
THE
CAP
ASSE~LY
420
(
BACK
CASE
GNO
a:;
C6~
~EAT
SINK
GNU
PM
I
PC2
B3
AS3
03
L
(T2-
T2
OIL2-2(~
(YELLOW)
r
-i
04
I
b04~
AS4
I~L_C
CO
~I~L
-
Si
RED(PLG3-31
CA
C-)
C
A
I)
4
1~1~~l
CT3
~
\
K.
JY
0
CA
CA
28C
C)
.~
(U
CT4
U
C)
C)
-
45C
C-)
CA
CA
o o
B
A
C
0
o
o
PC
15
YI
WHT)PLG3-9)
ii
~
~
~
~
RC4/PLG4
RC5/PLG5
~iJ
Rd/P
44A(F4C(4-J1
26A(RC)4-F
14A(TPI-BOTT)
LGI
40A
(NC
14-N)
38A
(
PC
I
4-MI
37A(S2-WIPEP(
36A(RC
14-LI
31A(RCI4-H)
~JRc2/PLG2
PC
I
Prfl
I
r,-pnq
I
WHT(CT3-(
I
(CT2(
T(CT2I
rICTA)
(
(
C
~RC3/PLG3
r(06-c2E))
0(CT))
ED(
CT
I
ED(CT4)
WHT(CI-NEG(
)~)
R~U(CIP0S(
RC6/PLG6
OM-171
006
Page
10
l58(Pt.GI
-3)
____________________
DLK/WHT(RCIO-2
____________________
81.ACICIPLGIO-
I
EII~~III2I
r
8RN/WHT
(
10-4
J
20)PLG
li-I)
IA)PLGI
-8)
16B(PLGI
1-2)
YELLOWIRCI
1-5)
SLtE)PCI
-2)
YELLOWIRCI
I
-7)
~
1~A~1RdI
I
-6
____________________________________
~
BLACK)RCII-8)
I
WHITE)RCII-4)
~EEN(RCl0-9)
REOIRC))-I
FM
I~
l~AY)RC)l3
I
SPA
PCIO-5)
BL~/WNI~(RCI0-6)
3D)PLGI
I-i
________________________________________________________
BLLE/WHITE)T3)
~i~TFM)
i
1
SPAYCTO
__________________________
6
5
WHITE(FMI
1
GREEN)131
YELLOW(FM1
BLAcKCsPLrCE-r31
(
REDIF)l)
J
.ELLOW)FM)
_____________________________
&.K/WHT
)SPLICE-T3)
68)
SPLICE-T3
166)TE2-31
28)TE2-l)
>
47A)PLI)
30(PCIO-IO)
I
22AIPLGI-l
Iii
_________________
I58)SPLICE-T3)
~
20)SPLICE-13)>
23AI~Gl-7~
f~PL
987
IA)SPLICE-T3)1
PLGII
1981PC2-PPECI4II
SPL~E
I9AICPI-I)
f
TI
I
I
I
_______
_______
46A)PLG!
I
5>
2
21

-j
COIL
I
COIL
2
_~__~
~LGIl-61~~I
c~
~I
0.
0.
W1j1W
II
I
2A)SPI-AC3)
S2
I
I
I0.w
___
H
0.
I
I
3
I
35
<
I I
_________
U
34155)
AC2)
I
I
L
j
~1
0.
01.)
______________________
0.
0.-
4A(SPI-ACI)
______________
.~jI
oji
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I
T2
J
I
_________________________
__________________~]
~1
01
_____
I
r
_________
_________
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___
(7(7
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12
UI
Ui
0.
I
COIL
I
COIL
2
I
0.
~
__
H~H
______
51C)TEfl
~
7
LI
___
iT~
516)PC2-BAI
~
1
WHTIPLG6-I)~
-
____________
U
C2
lb
A
6
5
REO)PLG6-3
CR1
___
L~r
50B1PC2-B3>
ii
5OCITE2-6)
)
I
12
0.-I
~J
WHTIPLG6-4)
PEDIPLG6-2
2B>PC2-BF
___________
52C(TE~~
-
SD-169790-B
OM-171
006
Page
11
LI)
C~)
SECTION
7
PARTS
LIST
Figure
7-1.
Complete
Assembly
U)
ST-BOO
977
Co
C.)
0
C)
Co
Cu
r-.
Cu
Co
-t
C
Cu
Cu
-7
0
Cu
0)
0
U)
A
/\
LI)
-t
C)
V
C)
U)
-e
U)
C)
U)
U)
Cu
OM-171
006
Page
12
Figure
7-1.
Complete
Assembly
141
690...
GROMMET,
scr
No.
8/10
panel
hole
.281
sq
.197
high
4
171
180...
CIRCUIT
CARD,
control
1
152
249...
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147
995
CONNECTOR,
rect
skt
22-lBga
Amp
770904-3
15
158720...
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147
995
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
12
148
439...
CONNECTOR
&
SOCKETS,
(consisting
of)
3
147
995
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
10
164
899...
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147
995
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
3
147
507...
INSULATION,
PC
card
1
BLOCK,
term
20A
9P
1
LINK,
jumper
term
blk
20A
4
BRACKET,
mtg
PC
board
1
EDGE
TRIM,
style
62-1/16
black
w/clips
(order
by
ft)
itt
NUT,
10-32
push
on
8
CAPACITOR,
elctlt
1600uf400VDC
2
SCREW,
set
10-32
x
.750
4
CLAMP,
capacitor
2
NUT,
10-32
push
on
2
KNOB,
pointer
.875dia
x
.250
ID
1
RELAY,
end
24VDC
DPDT
1
POTENTIOMETER,
C
sltd
sft
liT
2W
10K
ohm
1
MODULE,
varistor/capacitor
4400
joule
1
CONNECTOR,
circ
4skt
rcpt
1
CONNECTOR
w/SOCKETS,
(consisting
of)
1
079
534
CONNECTOR,
circ
skt
push-in
14-l8ga
14
174
048...
TRANSFORMER,
current
(consisting
of)
1
166
578
TRANSFORMER,
current
1
162
854
TRANSFORMER,
current
1
161
309
TRANSFORMER,
current
1
168
522
TRANSFORMER,
current
1
170 682...
CASE
SECTION,
front/bottom/rear
(consisting
of)
1
161
135
NUT,
insert
.010-32
4
126 026...
LABEL,
warning
electric
shock
can
kill
3
145
743...
LUG,
univ
w/scr
600V
1
010
916...
CONNECTOR,
clamp
cable
.750
1
026
947...
STAND-OFF,
insul
.250-20
x
1.000
Ig
4
038
776...
STUD,
brs
.250-20
x
1.500
4
167
887...
BUS
BAR,
capacitors
2
132844...
CAPACITOR,
polyp
film
2.luf
1000VDC
3
147
386...
BLOCK,
term
70A
3P
1
170414...
COVER,
capacitor
1
127
363...
LABEL,
warning
electric
shock
1
169 810...
CIRCUIT
CARD,
interconnecting
1
168
847...
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147
995
CONNECTOR,
rect
skt
22-l8ga
12
170 624...
RESISTOR
W/LEADS
1
169
814...
CIRCUIT
CARD,
interconnecting
1
170 565...
DIODE,
fast
recovery
30A
1000V
5
174
046...
CAPACITOR
ASSEMBLY
1
163472...
TRANSISTOR,
IGBT
module
75A
600V
2
006334...
THERMOSTAT,
NC
1
131
828...
RECTIFIER,
integ
100A
1200V
1
024
103...
BLANK,
snap-in
nyl
.75Omtg
hole
1
126416...
126415...
HANDLE,
molded
.~
..
1
CLAMP,
saddle
~.
-
1
WRAPPER
1
LABEL,
warning
general
precautionary
1
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
PCi....
PLG1...
PLG2...
PLG3-5.
PLG6...
4
TE2
....038832...
601219...
5
145453...
6
099037...
7
136190...
8
....
C1,2
....
151
821
155517...
9
006426...
148297...
10
097922...
...11....
CR1
....106462...
Al
073562...
13....
VCM1
...
164849...
14....
RC15
...167
723...
15....
RC14
...
143976
CT1...
CT2...
CT3...
CT4...
...22....
C3-5
TEl....
...24
+
PC2....
PLO1O
...26
R16....
...27
PC3....
28...
D5-7,9
...29
C6
...30....
Q5,6....
TP1....
...32
SRi....
36
+167886...
147876...
OM-171
006
Page
13
Figure
7-1.
Complete
Assembly
(Continued)
128
803...
BAR,
support
heat
sink
top
1
169
325...
HEAT
SINK,
power
module
1
161
330...
BAR,
support
heat
sink
bottom
1
148 828...
BRACKET,
mtg
fan
motor
1
170692...
MOTOR,
fan
1
170 694...
BLADE,
fan
6.500
5wg
3odeg
1
605
525...
NUT,
.312-24
stl
elastic
stop
1
168413...
DIODE,
fast
recovery6oA
1000V
1
171
883...
TRANSISTOR,
mosfet
45A
500V
4
168
510...
STABILIZER
1
170
598...
TRANSFORMER,
control
(consisting
of)
1
163
467
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147995
CONNECTOR,
rectskt22-l8ga
9
168
845
CONNECTOR
&
SOCKETS,
(consisting
of)
1
147
996
CONNECTOR,
rect
pin
22-l8ga
12
027
878...
SWITCH,
lim
15A
125/25OVAC
SPDT
1
091
441
...
SWITCH,
tgl
3PST
40A
600V
1
153 664...
INSULATOR,
switch
power
1
170475...
TRANSFORMER,
pwr
main
1
143915...
MOUNT,
sgl
stud
1.5dia
x
1.000
Ig
.312-18
4
NAMEPLATE,
(order
by
model
and
serial
number)
1
LIGHT,
md
wht
lens
28V
1
SWITCH,
rocker
SPDT
4A
25OVAC
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.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
...38
FM
...42
D8
...45....
01-4....
...46
Z1
T3
PLG11
RC1O...
S3
Si
...51....
T1,2....
...52
54
PL1
....
170599...
S2
120376...
OM.171
006
Page
14
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Miller IHPS II 5 KW Owner's manual

Miller
Brand
Miller
Model
IHPS II 5 KW
Category
Welding System
Type
Owner's manual
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