Miller
July
1993
Form:
OM-148
109A
Effective
With
Serial
No.
KD463564
OWNERS
MANUAL
''~?
~
v~r'
~
Read
and
follow
these
instructions
and
all
U
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
install,
operate,
or
service
this
unit.
persons
U
For
help,
call
your
distributor
Call
your
distributor
if
you
do
not
understand
the
directions.
E~J
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
U
IHPS5
10-50
Induction
Heating
Power
Source
10
To
50
kHz
Induction
Heating
Output
5
kW
Output
At
100%
Duty
Cycle
Uses
Three-Phase
Input
Power
Protection
For
Overheating
14-Pin
Remote
Control
Receptacle
cover
7193
Ref.
$T-f51
674-A
'
1993
MILLER
Electric
Mig.
Co.
PRINTED
IN
USA
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
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
aquipment
which
has
been
used
for
operation
outside
of
the
specifications
for
I
he
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCNASE
AND
USE
BY
COMMER
CIAtJINDUSTRIAL
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
eaclusive
remedIes
shell
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
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
cuatomera
flak
and
espenae.
MILLERS
option
of
repair
or
replacement
will
be
FOB..
Factory
etAppleton,
Wisconsin,
or
FOB.
eta
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costa
of
any
kind
will
be
allowed.
TO
TNE
EXTENT
PERMITTED
BY
LAW,
TNE
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
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
OP
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
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
escluaion
of
incidenlal.
indirect,
special
or
consequential
damages.
so
the
above
limitation
or
esclusion
may
not
apply
to
you.
This
warranty
provides
ape
cilic
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada.
legiatation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
estent
that
they
may
not
be
waived,
the
limitations
and
esclusiona
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.
I
1
MILLERS
TRUE
BLUETTM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
XC,,
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
warrsntiea
and
Is
esclusive
with
no
other
guarantees
or
warranties
espresaed
or
implied.
LIMITED
WARRANTY
-
Sub(ect
to
the
terms
and
conditions
below,
MILLER
Electric
Remote
Controls
Mtg.
Co.,
Appleton.
Wisconsin,
warrants
to
Its
original
retail
purchaser
that
new
*
Accessory
Kits
MILLER
equipment
sold
after
the
eftectlve
date
of
this
limited
warranty
is
free
of
da-
Re
lacament
Parts
tects
in
material
and
workmanship
at
the
time
itis
shipped
by
MILLER.
TIltS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTtES.
EXPRESS
OR
r
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT-
MILLERS
True
Blue
Umited
Warranty
shall
not
apply
to:
NESS.
1.
Items
famished
by
MILLER,
but
manutactured
by
others,
such
as
engines
or
trade
acceaaoflea.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
In
the
event
of
such
a
failure
within
the
warranty
time
periods.
Alt
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
the
distributor.
I.
5YeareParta3YearaLabor
*
Original
main
power
rectifiers
2.
3
Yeare
Parts
and
Labor
Transtormer/Rectlfier
Power
Sources
*
Plasma
Arc
CuBing
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.
I
YaarPartsand
Labor
*
Motor
Driven
Guns
Process
Controllers
*
Water
Coolant
Systems
HF
Units
Grids
*
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trailers
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.)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
Plasma
Cutting
Torches
I
I
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
manufacturers
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
S~tyie
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
5/93a
INDUCTION
HEATING
SAFETY
PRECAUTIONS
Below
are
examples
of
the
precautionary
labels
found
Keep
all
labels
readable.
If
any
label
is
unreadable
or
on
the
power
source,
the
controller,
and
the
head
damaged,
order
replacements
tree
of
charge
by
calling
assembly.
Any
person
who
installs,
operates,
maintains,
414-735-4356.
or
services
this
equipment
must
know
and
follow
all
-
applicable
codes
and
occupational
safety
practices
as
well
as
the
precautions
on
these
labels.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
before
servicing.
Keep
all
panels
and
covers
securely
in
p
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
handlina
parts.
INDUCTION
HEATING
can
be
hazardous.
Read
and
follow
this
label
and
the
Owners
Manual
carefully.
Only
qualified
persons
are
to
install,
operate,
or
service
this
unit
according
to
all
applicable
codes
and
safety
practices.
Keep
children
away.
Read
NFPA
Standard
70,
National
Electrical
Code,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Oulncy,
MA
02269
and
CSA
Standard
C22.1,
Canadian
Electrical
Code
Part
1,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
Figure
1.
Power
Source
Label
Figure
3.
Controller
Label
WARNING
Do
Not
qemove,
Destroy,
Or
Cover
This
Label.
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
(MSDS8)
and
manufacturers
instructions
for
material
used.
a
AVERTISSEMENT
I
UN
CHOC
ELECTRIQUE
peut
etre
mortel.
deux.
Installation
et
raccordement
de
cette
machine
doivent
etre
conformes
a
tousles
codes
pertinents.
CHAFFAUGE
PAR
INDUCTION
peut
etre
hasar
Lire
le
manuel
dlnstructlons
avant
utlllsatlon.
Ne
pas
installer
sur
une
surface
combustible.
S-147
878
a
WARNING
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.
S.147
878
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.
t37
260
SR9_7/91
EMF
INFORMATION
N
OTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
__________________
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress.
Office
of
Technology
Assessment.
Biological
procedures:
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
1.
-
Keep
cables
close
together
by
twisting
or
taping
them.
Background
Paper.
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
.
there
is
now
a
very
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables
around
the
body.
cellular
level
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
ractical
produce
changes
in.
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
About
Pacemakers:
allow
us
to
draw
definite
conclusions
about
questions
of
possible
The
above
procedures
are
among
those
also
normally
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
I
or
avoid
potential
risks.
complete
information.
modl0,l
4/93
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
1
SECTION
2
-SPECIFICATIONS
.
~
1
SECTION
3
INSTALLATION
3-1.
Connecting
Transformer
To
Power
Source
................
-
2
3-2.
Remote
Control
Receptacle
Connections
And
Information
......
3
3-3.
Connecting
Input
Power
...........................
4
SECTION
4-OPERATION
.....................................
6
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
...............,............
8
5-2.
Overload
Protection
....,...,,..,.,.,,,......,,.,.,....
8
5-3.
Troubleshooting
...........................
8
SECTION
6
ELECTRICAL
DIAGRAMS
...............,........
9
SECTION
7
PARTS
LIST
Figure
7-1.
Complete
Assembly
12
OM-148
109A
7/93
SECTION
1
SAFETY
INFORMATION
modl.1
2/93
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
-~
1
Safety
Alert
Symbol
2
Signal
Word
2
2
\
WARNING
means
possible
death
I
or
serious
injury
can
happen.
MOVING
PARTS
can
injure,
injury
or
equipment
damage
can
Keep
away
from
moving
parts,
happen.
ELECTRIC
SHOCK
can
kiII)~
3
________________________________
CAUTION
means
possible
minor
Do
not
touch
we
e~t~I~
pa~s
Ii
~
when
operating
I
Result
Keep
all
panels
and
covers
closed
I
3
Statement
Of
Hazard
And
Disconnect
input
power
before
installing
Or
servicing.
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
______________________________________________________________________
6
Safety
Banner
6~
e
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2
SPECIFICATIONS
a
CAUTION
Figure
2-1.
Typical
Induction
Heating
System
OM-148
109
Page
1
Table
2-1.
Induction
Heating
Power
Source
Specification
Description
Type
Of
Output
10
To
50
kHz
Rated
Output
5
kW
At
100%
Duty
Cycle
Type
Of
Input
Power
Three-Phase.
230
Or
460
Volts
AC,
50/60
Hz
Input
Amperes
At
Rated
Output
20
Amperes
At
230
V;
10
Amperes
At
460
V
Overall
Dimensions
Length:
19-1/2
in
(495
mm);
Width:
11-1/2
in
(292
mm);
Height:
11-3/4
in
(298
mm)
Weight
Ship:
43
lb
(20
kg);
Net:
38
lb
(17
kg)
SECTION
3INSTALLATION
1
Output
Receptacle
TE4
.
2
Output
Receptacle
TE5
3
Connectors
From
Transformer
Connectors
from
transformer
may
be
connected
to
either
receptacle
TE4
or
TE5.
To
connect
to
receptacles,
align
key
way,
insert
connector,
and
turn
clockwise
until
tight.
3-1.
Connecting
Transformer
To
Power
Source
ST-150
751-B
Figure
3-1.
Connecting
Transformer
To
Power
Source
OM-148
109
Page
2
3-2.
Remote
Control
Receptacle
Connections
And
Information
1
Plug
2
Threaded
Collar
3
Keyway
4
14-Socket
Receptacle
RC9
To
connect
to
receptacle,
align
key
way,
insert
plug,
and
tighten
threaded
collar.
Socket
Information:
Remote
Contactor
A
+24
volts
dc.
8
Contact
closure
to
pin
A
completes
24
volts
dc
contactor
control
circuit.
Remote
Output
Control
C
Command
reference;
+10
volts dc.
D
Control
circuit
common.
E
Input
command
signal
(potentiometer
wiper
or
0
to
+10
volts
dc).
Power
Source
Fault
F,
J
Contact
closure
between
F
and
J
signals
power
source
failure
to
remote
control
device.
Remote
Metering
H
Current
output
signal
(12).
I
Actual
frequency
output
signal.
L
Average
power
output
signal.
M
Voltage
output
signal
(RMS).
N
Current
output
signal
(RMS).
K
Chassis
common.
sb7.i
*
3/93
-
Rel.
S-0004-A/
Ret
S-0750
/
Ret
ST-i
50751-B
Figure
3-2.
14-Socket
Receptacle
Connections
.3
OM-148
109
Page
3
3-3.
Connecting
Input
Power
Figure
3-3.
Input
Voltage
Jumper
Links
Location
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.
Remove
wrapper
to
check
jumper
links.
1
Terminal
Strip
TE2
2
Terminal
Strip
TE3
3
Input
Voltage
Jumper
Link
4
Input
Voltage
Label
Four
jumper
links
supplied.
Look
at
jumper
links
and
compare
link
posi
tion
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.
a
WARNING
ELECTRIC
SHOCK
can
kill.
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.
A.
Positioning
Jumper
Links
swam31
2/93
4
L1
230
460
230
~
APPLIES
TO
BOTH
TE2
AND
TE3
S-150
944
Tools
Needed:
c~~izJ=u
5/16
in
Ref.
ST~15O
761-A
OM-148
109
Page
4
B.
Connecting
Input
Power
Table
3-1.
Electrical
Service
Requirements*
Input
Voltage
230
460
Input
Amperes
At
Rated
Output
20
10
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes1
25
15
Input
Conductor
Size
In
AWG/KcmiI2
12 14
Max
Input
Conductor
Length
In
Feet
(Meters)3
138
(42)
359(110)
Grounding
Conductor
Size
In
AWG/KcmiI4
12
14
These
values
are
calculated
from
the
1990
edition
of
the
National
Electrical
Code
(NEC).
1
Recommended
fuse
or
circuit
breaker
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source.
Article
630-12(a)
of
NEC
allows
fuse
or
circuit
breaker
sizing
up
to
200%
of
rated
input
amperage.
2
Input
conductor
size
is
for
insulated
copper
wire
with
75C
rating
with
not
more
than
three
single
current-carrying
conductors
in
a
cable
or
raceway
(Table
310-16
of
NEC).
3
Maximum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
terminals
of
the
welding
power
source
(Articles
210-19
(a)
and
215-2(b)
of
NEC).
4
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).
S-o092-F
OM-148
109
Page
5
Have
only
qualified
persons
make
this
installation.
Remove
wrapper.
1
Line
Disconnect
Device
Of
Proper
Rating
Obtain
and
install
switch.
2
Input
Conductors
3
Grounding
Conductor
Select
size
and
length
using
Table
3-1.
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
Ground
Terminal
Connect
input
conductors
to
termi
nal
block
and
grounding
conductor
to
ground
terminal
in
power
source:
Install
and
connect
grounding
conductor
and
input
conductors
in
conduit
or
equivalent
to
deener
gized
line
disconnect
device.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
Reinstall
wrapper
panel.
7
Overcurrent
Protection
Select
type
and
size
using
Table
3-1.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
ST.150
761-c
Tools
Needed:
~
5/16
in
Figure
3-4.
Input
Power
Connections
SECTION
4
OPERATION
1
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
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.
1
Power
Adjustment
Control
2
Remote
Power
Adjustment
Switch
3
Power
Switch
Ref.
ST-151
674-A
Figure
4-1.
Controls
2
~
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
safety
glasses
with
side
shields.
Wear
dry
insulating
gloves
and
sb3.1
10(9*
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).
Ref.
ST-147
388-B
Figure
4-3.
Power
Adjustment
Control
OM-148
109
Page
6
Figure
4-6.
Sequence
Of
Induction
Heating
Process
I
Remote
Power
Adjustment
Switch
Use
switch
to
select
way
of
con
trolling
unit
output.
For
front
panel
control,
place
switch
in
Fanel
position.
For
remote
control,
place
switch
in
Remote
14
position.
Figure
4-4.
Remote
Power
Adjustment
Switch
1
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
On
po
sition.
2
Pilot
Light
Figure
4-5.
Power
Switch
Install
&
Connect))
Install
&
Connec~\~\
Install
&
Conne~\
~
Put
On
Turn
On
~
)
Power
Source
Transformer
&
I
Coolant
Supply,
I
Personal
Safety
Coolant
Supply,
_________________
Heating
Surfa~J,J
If
Required
}
I
Equipmen~,J)
If
Required
}
Position
worD)
Turn
~
10
Seconds
To
Heat
Wait
)
)
Unit
Ready
Near
Power
)
Heating
Surface
Switch
OM-148
109
Page
7
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.
5-1.
Routine
Maintenance
5-2.
Overload
Protection
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.
-1
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.
5-3.
Troubleshooting
READ
~
Sectio
SAFETY
BLOCKS
at
start
of
n
5
before
proceeding.
Table
5-1.
Troubleshooting
Trouble
Remedy
Section
No
heat
output.
Replace
building
line
fuse
or
reset
circuit
breaker.
3.3
Secure
transformer
plug
in
power
source
receptacle.
3-1
Check
and
replace
Power
switch
if
necessary.
No
heat
output;
fan
motor
continues
to
run,
Thermostat
TPI
open
(overheating).
Allow
fan
to
run;
the
thermostat
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.
3-3
3
Months
Tape
Or
Replace
Cracked
Output
Cable
Turn
Off
all
power
before
maintaining.
__c1\L~J
Clean
And
Tighten
Output
Connections
Ref.
ST-151
674-A
Figure
5-1.
Maintenance
Schedule
OM.148
109
Page
8
SECTION
6-
ELECTRICAL
DIAGRAMS
r~
~)
r)
0
0
Figure
6-1.
Circuit
Diagram
For
Induction
Heating
Power
Source
SC-145
434-0
230/
460
LO
8
PC~-6
PC~-5
r4~
PC6-2
PC6-3
PCA-
I
RC~-
2
PC5-
II
PC5-
I
PC5-2
H
PC
I
/PLG
I
PC2/PLG2
PC3/PLD3
PC4/PLD4
PC5/PLG5
RC6/PLG6
PC7/PLG7
PC8/PLG8
PC9/PLG9
/2
PCI-B
PCI4
24
I
A
>
25~<
PCI-A
10
C
~
I
12
~<
PCI-3
PEFCOM
I
D
>
26
<<
PC2-4
FAULT
I
F)
18
<<PC
-24
I
G
>
I
32
<<
PCB-9
FPEO
I
I
~
J6~<<
RC8-3
I
38
<<
PC8-7
VR,~
I
M
>
10
<<
PC8-8
N>
B
>_~__],<
PC2
-3
31
-~_I
K
~
PCI-12
POWEP
ADJUST
~
PCI-S
I
PANEL
PC2-5
32
U)
E
>
REMOTE
~
RC2-I
~f~ULT
2
J
PC3-2
PC3-
OM-148
109
Page
9
1~7C
1~II
364
P168-3?
25AIPLGI-6
42C
(PLO
1-3)
~:?
___________________
_fi
fi
38A(PLG8.7
264
(P102-4
I
UOA)PLG8-8)
4841PL0
I-Il)
31A(PLG8-2)
3241PLG8-91
44A(PLG2-()
r)
IC)
T
~HTlPLG9-l
T
(P169-2)
N0TE~
INSTALL
C13
WITH
ARROW
FACING
lEO
Figure
6-2.
Wiring
Diagram
For
Induction
Heating
Power
Source
'
L2fifi
LI~fi
8AISI
-BOT)
74(S
I-MID)
64(S)
-TOP)
IASIDI
Cl-AC
I
U
TE3
230
460
230
1E2
230
460
230
_J
~I ~I
~
H H
UI
Al
Al
(7 (A
(2
(2
LU
LI
U
LU (2
_J
0.
.J
CA
CCL
~I
~I
~t ~l
LII
UI
UI
UI
I
WI WI
~..i
QI
~
~I
~I
~OI 0,1
~I
nj)
ol
,iI
I
CA)
l 1
t
(A)
~l
07) 47)
(TI
COIL
2-2)
GND.
TE
I
PC
LU
I
U
0
C
U,
1~
24)5)
TOP)
44)5)
BOlT
28)
CO
CU
.
CO
42E
(
4-1(1
BACK
)
CASE
42D(HEAT
SINK
GND
GND
17A(PC
IdB
TOP2
r
loll
14A)PLG2-3
.lDl4
BOT2L
57A.-..
PED)PLGR-4
CT2
564
AS4
PEO~
T2
_______
LG5-_(2)
p
~1
I
-C
TOP
I
~J
L
ZI
INO2
WHITE
)
04
0(PLG5-i
I)
53B)Cl
BOT)
SPAT
TI
(
-2)~
TI
PC2
SNUI
296)RCIO-i)
~~~WHTPLG4IO;__
~I
~flFREDlPLGdE7,__
fl~WHTIPLGdil__
~
_________
~O6C__
I
,
TI)COfl
2-UI
AC)1012
WHT
I
P1139-A
I
578
IPLG3-2
RED
IPLGO-61
~
I
03
I
L__..i
WHITE
(
003
533,
r-1
I
D5
I
WI-IT(PLGS-2)
I
02
I
RED
42O)GND)
HEAT
SINK
UI
04
U
C
04
TI)COIL
I-U)
ANT
I
P105-7
I
~
0)
r
I
0)
I
RED
L
1(PLG5-8I
ZI
INDI
ASIQ
)
30A(RCIO-2)
50B)C2*
psi
AC2
ci1~
~
PC4/)5141312
PLGU
~oI9IAI7
PEO(O5-E
II
RED)
06-E2)
WlIT(05-02)
ANT
I
06-Gil
CAfl
O(7_Cfl
_32~_
PC5/
PLG5
334(81-CA)
)~25AIPCI4-CI
-
4
A
PCIA-G(
II~Hl35A)PI-CCW
-
22A)SPLICE
YEL)~
086
-
244(S(7ICE
YEL)ll~*~I!42CIPCI4-O
-
C
TE
4
____________
RED)
05-C2E
I
(A
C
TE5
32A)RC
4-I)
404
(
I
U-N)
384
1
PC
U-MI
OIU(RC
Id-HI
36A
18114-LI
575)06-E2
558106-Cl
I
_______________
PCI
/
PLGI
~P109
RC6iII~]
IOA)CPI-AI
4
6
RC9/
l~
110)181-61
(
PLG6~
420)64CC
CASE
GIO
PLG2
RC7/1~1
PLG81
4(11)173)
WHT)CTI
C
WHTICT2
RC2/
~PC3/
-fI~–-
LG7~JJ
.o,~PLG3
II~jJl
WHTICTI
C
(C
OM-148
109
Page
10
SD-145
980-D
OM-148
109
Page
11
17
18
2
3
4
5
16
-6
IS
14
13
12
56
55
19
54
1
27
-37
50
Cl)
m
C)
-I
0
z
-1
Cl)
r
C)
-I
36
35
38
32
39
*Included
w/item
14
34
48
I
-I
-J
ST-151
885-B
Figure
7-1.
Complete
Assembly
PLG1...
PLG2...
PLG3...
PLG4...
PLG5...
PLG6...
PLG8...
.3
4...TE2,3
5
...
CT1,2
PLG7...
..6
10
C3....
..11....CT3...
PLG9...
12...
RC14...
13
14
TE4,5
15
16
17.
18
19
20
.
21
..22....TE1...
..23....PC2...
PLG1O
24....Q5,6
..25....TP1...
26...
VR1-3
..27....SR1...
28
29
30
31
32
FM....
33
34
35.01-4...
36
.
.
D5,11-14
37
141
690
161
856
158
720
147
995
153
501
147
995
158
719
147
995
148
439
147
995
158
720
147
995
;95
163
467
147
995
147
507
038
081
601
219
162
855
145
453
161
327
132
844
161
329
110
941
147
817
153
501
147
995
086
022
126
026
129
525
145
691
126
416
126
415
147
876
024
103
145
743
010
916
147
386
144
483
158
719
147
995
163
472
032
810
098
747
131
828
161
331
145
689
161
330
148
828
146
932
000
366
132
951
131
467
147
947
163
822
Figure
7-1.
Complete
Assembly
Item
D~a.
No.
Mkgs.
Part
No.
Description
Quantity
GROMMET,
scrNo.
8/10
panel
hole
.281
sq
.197
high
4
CIRCUIT
CARD,
control
1
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skf22-l8ga
Amp
770904-3
12
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
6
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
2
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
10
CONNECTOR
&
SOCKETS,
(included
w/PC2)
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
12
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
3
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOft
rect
skt
22-1
8ga
Amp
770904-3
9
INSULATION,
PC
card
1
BLOCK,
term
20A
4P
2
LINK,
jumper
term
blk
20A
4
TRANSFORMER,
current
(consisting
of)
1
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-1
8ga
Amp
770904-3
4
BRACKET,
mtg
PC
board
1
INSULATOR,
tank
cap
1
CAPACITOR,
polyp
film
2.luf
1000VDC
2
BUS
BAR,
capacitors
2
CAPACITOR,
polyp
film
.85uf
500VAC
1
TRANSFORMER,
current
(consisting
of)
1
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
6
CONNECTOR,
circ
l4skt
sz
2orcpt
Amphenol
MS-3102A-20-27S
1
LABEL,
warning
electric
shock
can
kill
3
RECEPTACLE,
twik
insul
fern
(dinse
type)
50/70
series
2
WRAPPER
*
1
HANDLE,
molded
1
CLAMP,
saddle
1
LABEL,
warning
general
precautionary
1
.
BLANK,
snap-in
nyl
.75Omtg
hole
1
LUG,
univ
w/scr
600V
1
CONNECTOR,
clamp
cable
.750
1
BLOCK,
term
70A
3P
1
CIRCUIT
CARD,
interconnecting
1
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
22-l8ga
Amp
770904-3
2
TRANSISTOR,
IGBT
module
75A
600V
2
THERMOSTAT,
NC
1
VARISTOR
ASSEMBLY
1
RECTIFIER,
integ
100A
1200V
1
BAR,
support
heat
sink
top
1
HEAT
SINK,
power
module
1
BAR,
support
heat
sink
bottom
..~
1
BRACKET,
mtg
fan
motor
1
MOTOR,
fan
1
RING,
retainer
E
.250
shaft
grv
x
.O25thk
2
BLADE,
6.5
in
6wg
.250
bore
CW
I
TRANSISTOR,
mosfet
45A
500V
4
DIODE,
fast
recovery
30A
800V
5
CASE
SECTION,
front/bottom/rear
(consisting
of)
1
NUT,
insert
.312-18
4
OM-148
109
Page
13
137197
p
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