PWHT O271146g - Mil - en

OM-271146G 2016−12
Processes
Induction Heating
Description
Induction Heating Power Source
ProHeat 35
CE And Non CE Models
(For Stock Nos. 907689, and 907690)
For product information, File: Induction Heating

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

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Induction Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 5
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Serial Number and Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4. Connecting 3-Phase Input Power For 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-5. Connecting 3-Phase Input Power For 400/460 Volt IEC And CE Models . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. Coolant Jumper Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-7. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-9. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-10. Temperature Recorder Receptacle RC9 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . 20
5-11. Temperature Recorder Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-12. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-13. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-14. Locating Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-15. Attaching Welded Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-16. Using Contact Thermocouple Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-17. Using Non−contact Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-2. System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-3. Important System Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-4. Power Source/System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-4-1. Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-5. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-5-1. Temperature-Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-5-1-1. Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-5-1-2. Bake-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-5-1-3. PWHT (Post-Weld Heat Treat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-5-1-4. PWHT (Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-5-1-5. Custom Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-5-2. Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-5-3. Power vs Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-5-4. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-5-5. Rolling Inductor—Manual Or Temperature Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-6. Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-6-1. Temperature Based Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-6-1-1. Preheat, Bake-Out And PWHT Run Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-6-1-2. Custom Program (Not Applicable With Rolling Inductor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-6-2. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-6-3. Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-6-4. Power vs Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-7. Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-8. Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-9. Real-Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-10. System Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-2. Calibration Verification Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-3. Calibration Verification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-3-1. Initial Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-3-2. TC Input/Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-3-3. Finishing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 9 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 10 − DIAGNOSTICS & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-1. Operator Interface Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-2. Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-3. Limit Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-4. Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-5. Fault Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-6. Infrared Sensor Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-7. System Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-8. ProHeat 35 Firmware Versions And Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-9. Removing Wrapper and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10-10. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number

ProHeat 35 400-460V, CE 907690
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
July 13, 2015
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
272703A
EMF DATA SHEET FOR INDUCTION HEATING POWER SOURCE
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. is voluntarily providing the following infor
mation to assist European employers in carrying out their assessments to show compliance with Directive
2013/35/EU on the minimum health and safety requirements regarding the exposure of workers to the risks arising
from physical agents (electromagnetic fields).
Product/Apparatus Identification
Product Stock Number

PROHEAT 35, 400-460V (CE) 907690
Compliance Information Summary
Applicable regulation Directive 2014/35/EU

Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards None
Intended use ☒ for occupational use ☐ for use by laymen
Sensory effects need to be considered for workplace assessment ☐ YES ☒ NO
Non-thermal health effects need to be considered for workplace assessment ☒ YES ☐ NO
Thermal health effects need to be considered for workplace assessment ☐ YES ☒ NO
☒ Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐ Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐ Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
EMF Data for Non-thermal Health Effects

Minimum approach distances to pipe/coil where EMF exposure limit values are not exceeded (ELV Exposure Index ≤ 1)
Body Part
Output Power
Head Trunk Hand Thigh
35 kW 12 cm 14 cm 6 cm 12 cm
25 kW 11 cm 13 cm 4 cm 11 cm
15 kW 9 cm 11 cm 2 cm 9 cm
5 kW 4 cm 6 cm 0 cm 4 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%) 30 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%) 56 cm
Assessment performed by: Mike Madsen Date performed: 2016-03-18
276511A
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2015-09
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex- This group of symbols means Warning! Watch Out! ELECTRIC
plained in the text. SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Induction Heating Hazards

D Frequently inspect input power cord and ground conductor for dam-
The symbols shown below are used throughout this manual age or bare wiring – replace immediately if damaged – bare wiring
to call attention to and identify possible hazards. When you
can kill.
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is D Turn off all equipment when not in use.
only a summary of the more complete safety information D Do not use worn, damaged, undersized, or repaired cables.
found in the Safety Standards listed in Section 1-5. Read and
D Do not drape cables over your body.
follow all Safety Standards.
D Do not touch power circuit if you are in contact with the work, ground,
Only qualified persons should install, operate, maintain, and or another power circuit from a different machine.
repair this unit. D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
During operation, keep everybody, especially children, away.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
ELECTRIC SHOCK can kill. D Use GFCI protection when operating auxiliary equipment in damp or
wet locations.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus SIGNIFICANT DC VOLTAGE exists in inverter power
bars or connections are electrically live whenever sources AFTER removal of input power.
the output is on. The input power circuit and machine
internal circuits are also live when power is on. Incorrectly installed or D Turn Off inverter, disconnect input power, and discharge input
improperly grounded equipment is a hazard. capacitors according to instructions in Maintenance Section before
D Do not touch live electrical parts. touching any internal parts.
D Enclose any connecting bus bars and coolant fittings to prevent FUMES AND GASES can be hazardous.
unintentional contact.
D Wear dry, hole-free insulating gloves and body protection. Induction Heating of certain materials, adhesives,
D Insulate yourself from work and ground using dry insulating mats or and fluxes can produce fumes and gases. Breathing
covers big enough to prevent any physical contact with the work or these fumes and gases can be hazardous to your
ground. health.
D Additional safety precautions are required when any of the following D Keep your head out of the fumes. Do not breathe the fumes.
electrically hazardous conditions are present: in damp locations or D If inside, ventilate the area and/or use local forced ventilation to re-
while wearing wet clothing; on metal structures such as floors, grat- move fumes and gases. The recommended way to determine
ings, or scaffolds; when in cramped positions such as sitting, adequate ventilation is to sample for the composition and quantity of
kneeling, or lying; or when there is a high risk of unavoidable or acci- fumes and gases to which personnel are exposed.
dental contact with the workpiece or ground. For these conditions,
D If ventilation is poor, wear an approved air-supplied respirator.
see ANSI Z49.1 listed in Safety Standards. And, do not work alone!
D Read and understand the Safety Data Sheets (SDSs) and the man-
D Disconnect input power before installing or servicing this equip-
ufacturer’s instructions for adhesives, coatings, cleaners,
ment. Lockout/tagout input power according to OSHA 29 CFR
consumables, coolants, degreasers, fluxes, and metals.
1910.147 (see Safety Standards).
D Work in a confined space only if it is well ventilated, or while wearing
D Use only nonconductive coolant hoses with a minimum length of 18
an air-supplied respirator. Always have a trained watchperson near-
inches (457 mm) to provide isolation.
by. Fumes and gases from heating can displace air and lower the
D Properly install, ground, and operate this equipment according to its oxygen level causing injury or death. Be sure the breathing air is
Owner’s Manual and national, state, and local codes. safe.
D Always verify the supply ground − check and be sure that input pow- D Do not heat in locations near degreasing, cleaning, or spraying oper-
er cord ground wire is properly connected to ground terminal in ations. The heat can react with vapors to form highly toxic and
disconnect box or that cord plug is connected to a properly grounded irritating gases.
receptacle outlet.
D Do not overheat coated metals, such as galvanized, lead, or
D When making input connections, attach proper grounding cadmium plated steel, unless the coating is removed from the
conductor first − double-check connections. heated area, the area is well ventilated, and while wearing an air-
D Keep cords dry, free of oil and grease, and protected from hot metal supplied respirator. The coatings and any metals containing these
and sparks. elements can give off toxic fumes if overheated. See coating SDS
for temperature information.
OM-271146 Page 1
FIRE OR EXPLOSION hazard. INDUCTION HEATING can burn.
D Do not overheat parts. D Do not touch hot parts bare-handed.
D Watch for fire; keep extinguisher nearby. D Allow cooling period before handling parts or
D Keep flammables away from work area. equipment.
D Do not locate unit on, over, or near combustible surfaces. D Do not touch or handle induction head/coil during operation un-
D Do not install unit near flammables. less the equipment is designed and intended to be used in this
manner as specified in the owner’s manual.
D Do not operate where the atmosphere can contain flammable
dust, gas, or liquid vapors (such as gasoline). D Keep metal jewelry and other metal personal items away from
head/coil during operation.
D After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames. D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING EQUIPMENT can injure. STEAM AND HOT COOLANT can burn.
D Use handle and have person of adequate Hose may rupture if coolant overheats.
physical strength lift unit.
D Move unit with hand cart or similar device. D Never disconnect both ends of hose when in-
stalled on hot workpiece.
D For units without a handle, use equipment of adequate capacity to
D If coolant flow stops, leave one end of hose connected to allow
lift and support unit.
coolant to return to cooler and relieve pressure.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location. D Remove hose from hot workpiece to prevent damage.
D If using lift forks to move unit, be sure forks are long enough to D Visually inspect condition of hoses, cords, and cables before
extend beyond opposite side of unit. each use. Do not use damaged hoses, cords, or cables.
D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually OVERUSE can cause OVERHEATING
lifting heavy parts or equipment.
D Allow cooling period.
D Reduce output or reduce duty cycle before
FLYING METAL OR DIRT can injure eyes.
starting to heat again.
D Wear approved safety glasses with side D Follow rated duty cycle.
shields or wear face shield.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
MOVING PARTS can injure. boards or parts.
D Use proper static-proof bags and boxes to
D Keep away from moving parts such as fans.
store, move, or ship PC boards.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or H.F. RADIATION can cause interference.
guards for maintenance and troubleshooting as necessary.
D High-frequency (H.F.) can interfere with radio
D Reinstall doors, panels, covers, or guards when maintenance is navigation, safety services, computers, and
finished and before reconnecting input power. communications equipment.
D Have only qualified person familiar with elec-
ELECTRIC AND MAGNETIC FIELDS (EMF) tronic equipment perform this installation.
can affect Implanted Medical Devices. D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D Wearers of Pacemakers and other Implanted D If notified by the FCC about interference, stop using the equip-
Medical Devices should keep away. ment at once.
D Implanted Medical Device wearers should consult their doctor D Have the installation regularly checked and maintained.
and the device manufacturer before going near arc welding, spot D Keep high-frequency source doors and panels tightly shut.
welding, gouging, plasma arc cutting, or induction heating
operations.
OM-271146 Page 2
READ INSTRUCTIONS. BATTERY EXPLOSION can injure.
D Read and follow all labels and the Owner’s D Do not use induction equipment to charge bat-
Manual carefully before installing, operating, or teries or jump start vehicles unless it has a bat-
servicing unit. Read the safety information at tery charging feature designed for this purpose.
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to the
which contain chemicals known to the State of California to state of California to cause cancer, birth defects, or other re-
cause birth defects and, in some cases, cancer. (California productive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, National Electrical Code, NFPA Standard 70, from National Fire Protec-
is available as a free download from the American Welding Society at tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
http://www.aws.org or purchased from Global Engineering Documents www.nfpa.org and www. sparky.org).
(phone: 1-877-413-5184, website: www.global.ihs.com). Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Safety in Welding, Cutting, and Allied Processes, CSA Standard Standards Association, Standards Sales, 5060 Spectrum Way, Suite
W117.2, from Canadian Standards Association, Standards Sales, 5060 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS website: www.csagroup.org).
(phone: 800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
OSHA, Occupational Safety and Health Standards for General Industry, tion, ANSI Standard Z87.1, from American National Standards Institute,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten- site: www.ansi.org).
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone
tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the weld-
and magnetic fields (EMF). The current from arc welding (and allied pro- ing circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
7. Do not weld whilst carrying the welding power source or wire
following procedures in order to minimize exposure to EMF fields from
feeder.
the welding circuit:
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
1. Keep cables close together by twisting or taping them, or using a device manufacturer before performing or going near arc welding, spot
cable cover. welding, gouging, plasma arc cutting, or induction heating operations. If
cleared by your doctor, then following the above procedures is recom-
2. Do not place your body between welding cables. Arrange cables
mended.
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-271146 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom 2015−09fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles Ce groupe de symboles veut dire Avertissement! Attention! DANGER
joints ou sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures per- afférant pour les actions nécessaires afin d’éviter le danger.
sonnelles.
2-2. Dangers relatifs au soudage à l’arc

borne de terre du sectionneur ou que la fiche du cordon est raccor-
Les symboles présentés ci-après sont utilisés tout au long du dée à une prise correctement mise à la terre.
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
vigilant et suivez les directives mentionnées afin d’éviter tout teur de mise à la terre approprié et revérifier les connexions.
danger. Les consignes de sécurité présentées ci-après ne font D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
que résumer l’information contenue dans les normes de sécu- protégez−les contre les étincelles et les pièces métalliques chau-
rité énumérées à la section 2-5. Veuillez lire et respecter toutes des.
ces normes de sécurité. D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé. Le
L’installation, l’utilisation, l’entretien et les réparations ne remplacer immédiatement s’il l’est. Un fil dénudé peut entraîner la
doivent être confiés qu’à des personnes qualifiées. mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Au cours de l’utilisation, tenir toute personne à l’écart et plus D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
particulièrement les enfants.
sante ou mal épissés.
UNE DÉCHARGE ÉLECTRIQUE peut D Ne pas enrouler les câbles autour du corps.
entraîner la mort. D Ne pas toucher le circuit électrique si l’on est en contact avec la piè-
ce, la terre ou le circuit électrique d’une autre machine.
Le contact de composants électriques peut D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
provoquer des accidents mortels ou des brûlures
graves. Le circuit électrique et les barres collectrices champ les pièces endommagées. Entretenir l’appareil conformé-
ou les connexions de sortie sont sous tension ment à ce manuel.
lorsque l’appareil fonctionne. Le circuit d’alimentation et les circuits D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
internes de la machine sont également sous tension lorsque D S’assurer que tous les panneaux et couvercles sont correctement
l’alimentation est sur marche. Des équipements installés ou reliés à la en place.
borne de terre de manière incorrecte sont dangereux.
D Utiliser une protection différentielle lors de l’utilisation d’un équi-
D Ne pas toucher aux pièces électriques sous tension. pement auxiliaire dans des endroits humides ou mouillés.
D Protéger toutes les barres collectrices et les raccords de refroidis-
sement pour éviter de les toucher par inadvertance. Il reste une TENSION DC NON NÉGLIGEABLE dans
D Porter des gants isolants et des vêtements de protection secs et les sources de soudage onduleur UNE FOIS le
sans trous. moteur coupé.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou D Avant de toucher des organes internes, couper l’onduleur,
des tapis assez grands afin d’éviter tout contact physique avec la débrancher l’alimentation et décharger les condensateurs
pièce à couper ou le sol. d’alimentation conformément aux instructions indiquées dans la
D D’autres consignes de sécurité sont nécessaires dans les condi- partie maintenance.
tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures LES FUMÉES ET LES GAZ peuvent
métalliques telles que sols, grilles ou échafaudages ; en position être dangereux.
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou Le chauffage à induction de certains matériaux,
le sol. Dans ces conditions, voir ANSI Z49.1 énuméré dans les nor- adhésifs et flux génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour votre santé.
mes de sécurité. En outre, ne pas travailler seul !
D Couper l’alimentation d’entrée avant d’installer l’appareil ou d’effec- D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces
tuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation selon vapeurs.
la norme OSHA 29 CFR 1910.147(se reporter aux Principales nor- D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
mes de sécurité). niveau de l’arc pour l’évacuation des fumées et des gaz. Pour dé-
D N’utiliser que des tuyaux de refroidissement non conducteurs ayant terminer la bonne ventilation, il est recommandé de procéder à un
une longueur minimale de 457 mm pour garantir l’isolation. prélèvement pour la composition et la quantité de fumées et de gaz
D Installer le poste correctement et le mettre à la terre convenable- auxquels est exposé le personnel.
ment selon les consignes du manuel de l’opérateur et les normes D Si la ventilation est médiocre, porter un respirateur anti-vapeurs ap-
nationales, provinciales et locales. prouvé.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assu- D Lire et comprendre les fiches de données de sécurité et les instructions
rer que le fil de terre du cordon d’alimentation est bien raccordé à la du fabricant concernant les adhésifs, les revêtements, les nettoyants,
OM-271146 Page 4
les consommables, les produits de refroidissement, les dégraisseurs, D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace
les flux et les métaux. d’étincelles incandescentes ni de flammes.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
portant un respirateur. Demander toujours à un surveillant dûment Ne pas augmenter leur puissance; ne pas les ponter.
formé de se tenir à proximité. Des fumées et des gaz provenant du D Lire et comprendre les fiches de données de sécurité et les instruc-
chauffage peuvent déplacer l’air, abaisser le niveau d’oxygène et tions du fabricant concernant les adhésifs, les revêtements, les
provoquer des lésions ou des accidents mortels. S’assurer que l’air nettoyants, les consommables, les produits de refroidissement, les
ambiant ne présente aucun danger. dégraisseurs, les flux et les métaux.
D Ne pas chauffer dans des endroits se trouvant à proximité d’opéra- D Porter un équipement de protection pour le corps fait d’un matériau
tions de dégraissage, de nettoyage ou de pulvérisation. La chaleur résistant et ignifuge (cuir, coton robuste, laine). La protection du
peut réagir en présence de vapeurs et former des gaz hautement corps comporte des vêtements sans huile comme par ex. des gants
toxiques et irritants. de cuir, une chemise solide, des pantalons sans revers, des
D Ne pas surchauffer des métaux munis d’un revêtement tels que l’acier chaussures hautes et une casquette.
galvanisé, plaqué au plomb ou au cadmium, à moins que le revêtement
ne soit enlevé de la zone chauffée, que la zone soit bien ventilée et, si LE CHAUFFAGE PAR INDUCTION peut
nécessaire, en portant un respirateur. Les revêtements et tous les mé- provoquer des brûlures.
taux contenant ces éléments peuvent dégager des fumées toxiques
s’ils sont surchauffés. Voir les informations concernant la température D Ne pas toucher des parties chaudes à mains
dans les spécifications de revêtement SDS. nues.
D Laisser refroidir les composants ou équipe-
Risque D’INCENDIE OU ments avant de les manipuler.
D’EXPLOSION. D Ne pas toucher ou manipuler les câbles/enroulements d’induc-
D Ne pas surchauffer les composants . tion durant l’opération à moins que l’équipement soit conçu à cet
D Attention aux risques d’incendie: tenir un ex- effet comme indiqué dans le manuel d’utilisateur.
tincteur à proximité. D Tenir les bijoux et autres objets personnels en métal éloignés de la
D Stocker des produits inflammables hors de la zone de travail. tête/de l’enroulement pendant le fonctionnement.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces D Ne pas toucher aux pièces chaudes, utiliser les outils recom-
inflammables. mandés et porter des gants de soudage et des vêtements épais
D Ne pas installer l’appareil à proximité de produits inflammables. pour éviter les brûlures.
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance
D Les porteurs d’implants médicaux doivent consulter leur médecin
LA CHUTE DE L’ÉQUIPEMENT peut et le fabricant du dispositif avant de s’approcher de la zone où se
provoquer des blessures. déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par induction.
D Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soule-
ver l’appareil. LE LIQUIDE DE REFROIDISSEMENT CHAUD ET
D Déplacer l’appareil à l’aide d’un chariot ou d’un engin similaire. LA VAPEUR peuvent causer des brûlures.
D Pour les unités sans poignée, utiliser un équipement de levage de
Si le liquide de refroidissement est en surchauffe, un
capacité suffisante pour lever l’appareil. boyau pourrait se sectionner.
D Tenir l’équipement (câbles et cordons) à distance des véhicules D Ne jamais débrancher les deux extrémités du
mobiles lors de toute opération en hauteur. tuyau lorsque l’appareil est installé sur une
D En utilisant des fourches de levage pour déplacer l’unité, s’assu- pièce de travail chaude.
rer que les fourches sont suffisamment longues pour dépasser du D Si le liquide de refroidissement cesse de s’écouler, laisser une
côté opposé de l’appareil.
extrémité du tuyau branchée pour permettre au liquide de
D Suivre les consignes du Manuel des applications pour l’équation refroidissement chaud de revenir au refroidisseur et
de levage NIOSH révisée (Publication Nº94−110) lors du levage dépressuriser.
manuelle de pièces ou équipements lourds. D Pour éviter tout risque de dommage, retirer le tuyau de la pièce de
travail chaude.
DES PIECES DE METAL ou DES D Effectuer une inspection visuelle des boyaux, cordons et câbles
SALETES peuvent provoquer des avant chaque utilisation. Ne pas utiliser des boyaux, cordons ou
blessures dans les yeux. câbles endommagés.
D Porter des lunettes de sécurité à coques latéra-
les ou un écran facial. L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
provoquer des blessures. D Prévoir une période de refroidissement
D Réduire le courant de sortie ou le facteur de mar-
D S’abstenir de toucher des organes mobiles tels che avant de recommencer le chauffage.
que des ventilateurs. D Respecter le cycle opératoire nominal.
D Maintenir fermés et verrouillés les portes, panneaux, recouvre-
ments et dispositifs de protection.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et autres
implants médicaux doivent rester à distance.
OM-271146 Page 5
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES CHARGES ÉLECTROSTATIQUES
D Maintenir soigneusement fermés les portes et les panneaux des
peuvent endommager les circuits im- sources de haute fréquence.
primés.
LIRE LES INSTRUCTIONS.
D Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces. D Lire et appliquer les instructions sur les
D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé- étiquettes et le Mode d’emploi avant
placer ou expédier des cartes PC. l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
LE RAYONNEMENT HAUTE FRÉ- début du manuel et dans chaque section.
QUENCE (HF) risque de provoquer D N’utiliser que les pièces de rechange recommandées par le
des interférences. constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
D Le rayonnement haute fréquence (HF) peut manuels d’utilisateurs, les normes nationales, provinciales et de
provoquer des interférences avec les équipe- l’industrie, ainsi que les codes municipaux.
ments de radio-navigation et de communication,
les services de sécurité et les ordinateurs. L’EXPLOSION DE LA BATTERIE peut
D Demander seulement à des personnes qualifiées familiarisées avec provoquer des blessures.
des équipements électroniques de faire fonctionner l’installation.
D Ne pas utiliser l’appareil de soudage pour
D L’utilisateur est tenu de faire corriger rapidement par un électricien charger des batteries ou faire démarrer des
qualifié les interférences résultant de l’installation. véhicules à l’aide de câbles de démarrage, sauf
D Si le FCC signale des interférences, arrêter immédiatement l’appa- si l’appareil dispose d’une fonctionnalité de
reil. charge de batterie destinée à cet usage.
2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des Ce produit contient des éléments chimiques, dont le plomb,
fumées et des gaz qui contiennent des produits chimiques reconnus par l’État de Californie pour leur caractère
dont l’État de Californie reconnaît qu’ils provoquent des cancérogène ainsi que provoquant des malformations
malformations congénitales et, dans certains cas, des cancers. congénitales ou autres problèmes de procréation. Se laver les
(Code de santé et de sécurité de Californie, chapitre 25249.5 mains après toute manipulation.
et suivants).
2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
from Global Engineering Documents (phone: 1-877-413-5184, website: Standards Association, Standards Sales, 5060 Spectrum Way, Suite
www.global.ihs.com). 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
Safety in Welding, Cutting, and Allied Processes, CSA Standard website: www.csagroup.org).
W117.2, from Canadian Standards Association, Standards Sales, 5060 Safe Practice For Occupational And Educational Eye And Face Protec-
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS tion, ANSI Standard Z87.1, from American National Standards Institute,
(phone: 800-463-6727, website: www.csagroup.org). 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
OSHA, Occupational Safety and Health Standards for General Industry, site: www.ansi.org).
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Applications Manual for the Revised NIOSH Lifting Equation, The Na-
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone www.cdc.gov/NIOSH).
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs 3. Ne pas courber et ne pas entourer les câbles autour de votre
électromagnétiques (CEM) à certains endroits. Le courant issu d’un corps.
soudage à l’arc (et de procédés connexes, y compris le soudage par 4. Maintenir la tête et le torse aussi loin que possible du matériel du
points, le gougeage, le découpage plasma et les opérations de circuit de soudage.
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits 5. Connecter la pince sur la pièce aussi près que possible de la
peuvent causer interférence à certains implants médicaux, p. ex. les soudure.
stimulateurs cardiaques. Des mesures de protection pour les porteurs 6. Ne pas travailler à proximité d’une source de soudage, ni
d’implants médicaux doivent être prises: Limiter par exemple tout accès s’asseoir ou se pencher dessus.
aux passants ou procéder à une évaluation des risques individuels pour 7. Ne pas souder tout en portant la source de soudage ou le
les soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir.
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage: En ce qui concerne les implants médicaux :
1. Rassembler les câbles en les torsadant ou en les attachant avec Les porteurs d’implants doivent d’abord consulter leur médecin avant de
du ruban adhésif ou avec une housse. s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
médecin approuve, il est recommandé de suivre les procédures précé-
câbles d’un côté et à distance de l’opérateur.
dentes.
OM-271146 Page 6
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not wear wet or damaged gloves.
Safe56 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Induction heating can cause injury or burns from hot items such as rings, watches, or parts.
Safe74 2012−07
Do not wear metal jewelry and other metal personal items such as rings and watches during operation.
Safe75 2012−07
Induction heating sparks can cause fire. Do not overheat parts and adhesives.
Safe76 2012−07
Keep flammables away from heating operation. Do not heat near flammables.
Safe77 2012−07
Heating sparks can cause fires. Have a fire extinguisher nearby and have a watchperson ready to use it.
Safe78 2012−07
Breathing heating fumes can be hazardous to your health. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
Safe79 2012−07
Keep your head out of the fumes.
Safe80 2012−07
OM-271146 Page 7
Use forced ventilation or local exhaust to remove the fumes.
Safe81 2012−07
Use ventilating fan to remove fumes.
Safe82 2012−07
Always wear safety glasses or goggles during and around heating operations to prevent possible injury.
Safe83 2012−07
Wear either safety glasses or full goggles depending on type of operation and nearby processes.
Safe84 2012−07
Do not remove or paint over (cover) the label.
Safe20 2012−05
Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
? V
? A Consult rating label for input power requirements.
Safe34 2012−05
Become trained and read the instructions and labels before working on machine.
Safe35 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait after power is
V turned off before working on unit, OR check input capacitor voltage,
and be sure it is near 0 before touching any parts.
V Safe42 2012−05
OM-271146 Page 8
Connect green or green/yellow grounding conductor to ground
terminal.
Connect input conductors (L1, L2 And L3) to line terminals.
Safe86 2012−06
Become trained and read the instructions before working on the

machine or heating.
Safe85 2012−06
3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.
A Amperage Line Connection Three Phase
V Volts
I1 Primary Current Percent
Alternating
Current I2 Rated Current Remote
X Duty Cycle
U1 Primary Voltage Panel/Local
IP Degree Of
Protection U2 Load Voltage High Temperature
Hz Hertz Read Instructions Voltage Input
Three Phase
Circuit Protection Static Frequency Off
Converter-Transfo
rmer-Frequency
Converter
Output On
I1max Rated Maximum

Supply Current
Increase Induction Heating
Maximum Power
P1max Consumption
OM-271146 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Serial Number and Rating Label Location

The serial number and rating information for the power source is located on the front of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-4 and 5-5 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 104F ( 40C).
Amperes Input at
Required Rated Load Output
Output Rated Output Overall
Reflective 50 or 60 Hz, Weight
Frequency Three-Phase Dimensions
Inductance
Single Output Dual Output 400 V 460 V 575 V kVA kW
Length: 36.75 in.
35 kW At 35 kW At
(933 mm)
100% Duty 100% Duty
2.5 To 50 Width: 21.75 in. 227 lb
5 To 30 kHz Cycle Cycle 60 A 50 A 40 A 39 37
μh (553 mm) (103 kg)
350 A (RMS), 700 A (RMS),
Height: 27.5 in.
700 V (RMS) 700 V (RMS)
(699 mm)
4-3. Environmental Specifications
A. IP Rating
IP Rating
IP23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding (heating) outside during precipitation
unless sheltered.
Ref. IP23 2014−06
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 33.37mW (or the short−circuit power Ssc is greater than
112,138,497.99). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
OM-271146 Page 10
C. Temperature Specifications For Miller ProHeat 35 Rolling Inductor Cold Climate Operation
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
ÇÇÇÇ ProHeat Cooler Rolling Inductor Heating Cables
°C
ÇÇÇÇ °F
ÇÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇ
Storage
ÇÇÇÇÇ Operation Storage Operation Storage Operation Storage Operation
ÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ

ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
60 140
ÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ

ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
55 131 Reduced Reduced
efficiencies efficiencies
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
50 122 above 40°C above 40°C
45 113
40
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇÇ
104
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
35 95
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
30 86
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
25 77
20 68
15
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇÇ
59
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
10 50
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
5 41
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
0 32
−5 23
ÇÇÇÇ
−10
ÇÇÇÇÇ
ÇÇÇÇÇ
14
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇ
−15
ÇÇÇÇÇ
ÇÇÇÇÇ5
ÇÇÇÇÇ ÇÇÇÇ Energize Energize Energize
ÇÇÇÇ ÇÇÇÇÇ
ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇ
−20 -4 system system system
frequently to frequently to frequently to
ÇÇÇÇ
ÇÇÇÇÇ
−25 -13 maintain maintain maintain
ÇÇÇÇ
ÇÇÇÇÇ
−30 -22 coolant coolant coolant
Store dry temperature Store dry temperature Store dry temperature
ÇÇÇÇ
ÇÇÇÇÇ
−35 -31 above 14°F above 14°F above 14°F
−40 -40 (−10°C). (−10°C). (−10°C).
277088-A
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Not Recommended
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
With Qualifications
Normal Operation With Coolant
NOTICE − The Miller ProHeat 35 Rolling Inductor is rated for operation between 14° F and 140° F (−10° C to 60° C). For operation at -40° F to
14° F (−40° C to -10° C), take the following precautions to prevent equipment damage:
• Connect coolant lines to Rolling Inductor when dry, or when ambient temperature is above −4° F (−20° C).
• Operate ProHeat 35 Heavy Duty Induction Cooler only in temperatures between 14° F and 104° F (−10° C to 40° C) while operating Rolling Inductor/
Liquid Cooled Cables.
• Always use Miller Coolant (Miller Part Number 043810).
• Coolant must flow continuously through the Rolling Inductor/liquid cooled cables, and power must be applied to the Rolling Inductor /liquid cooled
cables at regular intervals to maintain a coolant temperature of at least 14° F (−10° C).
• Store Rolling Inductor/liquid cooled cables dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of the Rolling Inductor
and power cable.
• Store ProHeat 35 Heavy Duty Induction Cooler at a temperature between−4° F and 131° F(−20° C to 55° C).
. Coolant will not begin to flow until it is 14° F (−10° C).

NOTICE − For colder storage, the cooler must be stored dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of coolant
lines, filter bowls, pump, flow indicator, and heat exchanger.
OM-271146 Page 11
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement ! Do not move or operate unit

where it could tip.
OR
2
Location And Airflow 3 ! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in.
(460 mm) 18 in. 1 Lifting Eye
(460 mm)
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3 Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
18 in.
803992-B loc_large 2015-04
(460 mm)
5-2. Dimensions And Weights
Dimensions
*
A
27.5 in. (699 mm)
A
B 21.75 in. (553 mm)
C 36.75 in. (933 mm)
Weight
C
B 227 lb (103 Kg)
* Lifting Eye Weight Rating

803 992-B 600 lb (272 kg) Maximum
OM-271146 Page 12
5-3. Electrical Service Guide Elec Serv 2015−05
This equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50 Hz
60 Hz 3 Phase
3 Phase
Input Voltage (V) 400 460 575
Rated Maximum Supply Current I1max (A) 60 50 40
Maximum Effective Supply Current I1eff (A) 60 50 40
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2 70 60 50
Normal Operating Fuses 3 90 80 60
Min Input Conductor Size In AWG (mm2) 4 6 (16) 8 (10) 8 (10)
Max Recommended Input Conductor Length In Feet (Meters) 242 (74) 207 (63) 323 (99)
Min Grounding Conductor Size In AWG (mm2) 4 8 (10) 8 (10) 10 (6)
Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
Notes
OM-271146 Page 13
5-4. Connecting 3-Phase Input Power For 460/575 Volt Models
3
GND/PE Earth Ground
10
5 6 3
Tools Needed:
3/8 in.
input3 2015−01 / 803 994-E
OM-271146 Page 14
5-4. Connecting 3-Phase Input Power For 460/575 Volt Models (continued)
! Installation must meet all National age available at site. Connect input conductors L1, L2 and L3 to
and Local Codes − have only qualified welding power source line terminals.
1 Input Power Conductors (Customer
persons make this installation. Supplied Cord) Close and secure access door on welding
power source.
! Disconnect and lockout/tagout input Select size and length of conductors using
power before connecting input con- Section 5-3. Conductors must comply with Disconnect Device Input Power Connec-
ductors from unit. Follow established national, state, and local electrical codes. If tions
procedures regarding the installation applicable, use lugs of proper amperage 7 Disconnect Device (switch shown in
and removal of lockout/tagout de- capacity and correct hole size. OFF position)
vices. 8 Disconnect Device (Supply) Grounding
Power Source Input Power Connections
Terminal
! Make input power connections to the 2 Strain Relief (Customer Supplied)
welding power source first. 9 Disconnect Device Line Terminals
Install strain relief of proper size for unit and Connect green or green/yellow grounding
! Always connect green or green/yel- conductors. Route conductors (cord) conductor to disconnect device grounding
low conductor to supply grounding through strain relief. Tighten strain relief. terminal first.
terminal first, and never to a line ter-
3 Power Source Grounding Terminal Connect input conductors L1, L2, And L3 to
minal.
disconnect device line terminals.
4 Green Or Green/Yellow Grounding
. The circuitry in this unit automatically Conductor 10 Over-Current Protection
adapts the power source to the primary Select type and size of over-current protec-
voltage being applied. Check input volt- Connect green or green/yellow grounding
tion using Section 5-3 (fused disconnect
age available at site. This unit can be conductor to welding power source ground-
switch shown).
connected to either 460 or 575 VAC input ing terminal first.
Close and secure door on line disconnect de-
power. 5 Power Source Line Terminals vice. Follow established lockout/tagout pro-
See rating label on unit and check input volt- 6 Input Conductors L1, L2 And L3 cedures to put unit in service.
input3 2015−01
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-271146 Page 15
5-5. Connecting 3-Phase Input Power For 400/460 Volt IEC And CE Models
3
GND/PE Earth Ground
10
6
5
Tools Needed: 3
3/8 in.
5/32 in.
Input3 2015-01 / 272 715-A
OM-271146 Page 16
5-5. Connecting 3-Phase Input Power For 400/460 Volt IEC And CE Models (continued)
! Installation must meet all National age available at site. Connect input conductors L1, L2 and L3 to
and Local Codes − have only qualified welding power source line terminals.
1 Input Power Conductors (Customer
persons make this installation. Supplied Cord) Close and secure access door on welding
power source.
! Disconnect and lockout/tagout input Select size and length of conductors using
power before connecting input con- Section 5-3. Conductors must comply with Disconnect Device Input Power Connec-
ductors from unit. Follow established national, state, and local electrical codes. If tions
procedures regarding the installation applicable, use lugs of proper amperage 7 Disconnect Device (switch shown in
and removal of lockout/tagout de- capacity and correct hole size. OFF position)
vices. 8 Disconnect Device (Supply) Grounding
Power Source Input Power Connections
Terminal
! Make input power connections to the 2 Strain Relief (Customer Supplied)
welding power source first. 9 Disconnect Device Line Terminals
Install strain relief of proper size for unit and Connect green or green/yellow grounding
! Always connect green or green/yel- conductors. Route conductors (cord) conductor to disconnect device grounding
low conductor to supply grounding through strain relief. Tighten strain relief. terminal first.
terminal first, and never to a line ter-
3 Power Source Grounding Terminal Connect input conductors L1, L2, And L3 to
minal.
disconnect device line terminals.
4 Green Or Green/Yellow Grounding
. The circuitry in this unit automatically Conductor 10 Over-Current Protection
adapts the power source to the primary Select type and size of over-current protec-
voltage being applied. Check input volt- Connect green or green/yellow grounding
tion using Section 5-3 (fused disconnect
age available at site. This unit can be conductor to welding power source ground-
switch shown).
connected to either 400 or 460 VAC input ing terminal first.
Close and secure door on line disconnect de-
power. 5 Power Source Line Terminals vice. Follow established lockout/tagout pro-
See rating label on unit and check input volt- 6 Input Conductors L1, L2 And L3 cedures to put unit in service.
input3 2015−01
5-6. Coolant Jumper Connections
276861-A
OM-271146 Page 17
5-7. Power Source Output Connections
2 1
Dual Air-Cooled
Output Connection
2 1 2 1
4 4
Dual Liquid-Cooled
Output Connection
2 1
Single Air-Cooled Single Liquid-Cooled

Output Connection Output Connection 5 5
2 1 2 1
5
4
3 3
Ref. 803 993-D / Ref. 804 217-A
! Steam and hot coolant can burn. Single Air-Cooled Output Connection . Blankets must be the same size.
Hose may rupture if coolant over-
heats. Connect air-cooled output extension cable Dual Liquid-Cooled Output Connection
Never disconnect both ends of to Output Connector 1 or Output
hose when installed on hot Connector 2. Connect Protective Plug to Connect liquid-cooled output extension
workpiece. If coolant flow stops, remaining Output Connector. cables to Output Connector 1 and Output
leave one end of hose connected to
Connector 2.
allow hot coolant to return to cooler
and relieve pressure. Remove hose Single Liquid-Cooled Output Connection
from hot workpiece to prevent dam- . Extension cables must be the same
age. Connect liquid-cooled output extension length: 10 ft (3 m), 25 ft (7.6 m), or 50
1 Output Connector 1 cable to Output Connector 1 or Output ft (15.2 m).
2 Output Connector 2 Connector 2. Connect Protective Plug to
3 Protective Plug remaining Output Connector. . Heating cables must be the same
4 Air-Cooled Extension Cable length: 30ft (9.1 m), 50 ft (15.2 m), 80ft
5 Liquid-Cooled Extension Cable Dual Air-Cooled Output Connection (24.2 m), or 140 ft (42.7 m).
The power source is capable of single or
dual output. When connected for single Connect air-cooled output extension . Total length of heating and extension
power output, up to 35 kW is available at cables to Output Connector 1 and Output cables must not exceed 360 ft (110 m).
the single output connection. When The extension cable is counted twice
Connector 2.
connected for dual power, output power is the length because it has a supply and
divided between the two output return hose.
connections. . Extension cables must be the same
! Do not move or disconnect cables length: 25 ft (7.6 m), 50 ft (15.2 m), or NOTICE − Use only Miller ProHeat acces-
while output is on. 75 ft (22.8 m). sories with a Miller ProHeat power source.
OM-271146 Page 18
5-8. Remote 14 Receptacle RC14 Information and Connections
1 Plug
2 Threaded Collar
3 Keyway
4 Remote 14 Receptacle RC14
3 (See Section 5-9)
To connect to receptacle, align key-
way, insert plug and tighten
threaded collar.
A J 4 NOTICE − Use only Miller ProHeat
K I
B accessories with a Miller ProHeat
2 1 C L N
D M G
H power source.
E F
803 993-D
5-9. Remote 14 Socket Information

Socket Socket Information
A +24 volts DC.

Remote Contactor
B Contact closure to A completes 24 volts DC contactor control circuit.
C Command reference; +10 volts DC.

D Control circuit common.
Remote Output Control
E Input command signal (potentiometer wiper or 0 to +10 volts DC).
G Travel sense detect.
Absence of internal contact closure between F and J signals power source fault to remote con-
F, J Power Source Fault
trol device (an external power source must be used).
H Tank 2 IRMS (1 volt/10 amperes).

I Actual frequency output signal (1 volt/10 kHz).
L Average power output signal (1 volt/10 kW).
Remote Metering
M Voltage output signal RMS (1 volt/100 volts).
N Total current output signal RMS (1 volt/100 amperes).
K Chassis common.
OM-271146 Page 19
5-10. Temperature Recorder Receptacle RC9 Information And Connections
1 Plug
3 2 Threaded Collar
3 Temperature Recorder
Receptacle RC9 (See Section
5-11)
To connect to receptacle, insert
2 1 plug and tighten threaded collar.
803 993-D
5-11. Temperature Recorder Socket Information

Socket No. Socket Information
1 Thermocouple No. 1 (TC1), 0-10 volt DC signal [0V = −50° F (−46° C), 10V = 1500° F (816° C)]
5 Signal Common
8 Unused
9 Unused
10 Chassis Ground
11 Unused
12 Unused
13 Unused
14 Unused
* The voltage to temperature calculation is:
(DC Volts Out x 155) − 50 = °F
(DC Volts Out x 86.1) − 45.4 = °C
The ProHeat display should read ±6 °F or ±3.3 °C.
OM-271146 Page 20
5-12. Secondary Insulation Protection
! Connect supplied ground
lead(s) between the
workpiece and power source
to provide proper secondary
insulation protection from a
short in the output circuit.
For single output, only one
ground lead is required. For
dual output , use both ground
leads.
Secondary insulation protection
circuitry automatically shuts down
the power source output if a
potentially hazardous condition
exists at the heating device
connected to the power source (e.g.
insulation has broken down on a
heating blanket causing the
conductor to come into contact with
the workpiece or a heating coil
touches the workpiece causing a
short in the output circuit).
1 Receptacles
2 Plug
To connect plug, align key with key-
way, insert end into receptacle, and
rotate plug until tight.
3 Handle
4 Magnet
. The secondary isolation magnet
must be in contact with bare
metal (free from rust, paint,
grease, etc.).
5 Workpiece
Use handle to place magnet on the
1 workpiece.
2
4
3
803 994-E / 272 889-A
OM-271146 Page 21
5-13. 115 Volt AC Duplex Receptacle And Supplementary Protector
1 115 VAC 2.5 A Single-Phase
AC Receptacle RC1
2 Supplementary Protector CB1
(2.5 A)
The receptacle supplies nominal 115
volts AC auxiliary power for use with
the optional digital recorder. Maxi-
mum output from receptacle is 2.5
amperes.
1 CB1 protects 115 volt receptacle
RC1 from overload. If CB1 opens,
2 1 RC1 does not work.
803 993-D
5-14. Locating Thermocouples
Thermocouple location is one of the most critical steps in the Heat Treatment Operation.
Thermocouples shall be located as follows to provide a survey of heating uniformly and enable time and temperature control:
1. Locate thermocouples to ensure that the full area of the heat band is monitored.
S The code normally specifies the number of thermocouples to be used based on the pipe diameter.
S The control thermocouple is placed in the plane of the weld (center of the heat zone).
S The control thermocouple is placed at the top of the pipe in a standard pipe joint configuration. In other applications, the thermocouple
should be located in the hottest portion of the weldment to be stress relieved.
2. Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due to heat convection or
conduction, and have additional thermocouples applied.
3. Attach a spare thermocouple beside control thermocouples.
4. Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces.
5. Physically inspect all thermocouples for continuity and mark them by an identification number corresponding to the recorder channel.
6. Match the drawings of the workpiece indicating the numerous thermocouple locations, controlling thermocouple locations, etc. to weld identifi-
cation information.
7. The system is equipped with 3-pin thermocouple connections at the front of the unit. Six thermocouples can be attached to the power source.
S The system is equipped with 3-pin connectors to accommodate shielded extension cables. The shielded cables protect from electrical
interference.
8. Type K thermocouple wire has a positive and negative wire. The positive wire is marked as solid yellow or striped yellow. The connector screw
terminals are marked positive and negative. Be sure to attach the wire to the connector with proper polarity.
9. Multiple type K thermocouple devices are supported, such as contact TC probes, welded on TC wire, and IR sensors with type K output. IR
sensors with 4−20 mA outputs are also supported.
OM-271146 Page 22
10. The following describes the thermocouple routing from work to power source.
S Type K thermocouple wire (two wire) is attached directly to the workpiece using a Thermocouple Attachment Unit (see next section for
information on attaching thermocouples).
S The other end is fitted with a 2-pin type K connector.
S The 2-pin connector plugs into the 3-pin composite extension cable. The extension cable has a six-channel block of 3-pin female connec-
tors. The pin size locates the position of the 2-pin connector on the extension.
S The extension cable contains six, 3-wire bundles of shielded cable.
S The 3-pin male extension cable plugs into the 3-pin female connector on the front of the power source.
804 320-A
For temperature control mode, the power

source must have (as a minimum) one
. Do NOT weld thermocouples to work- 3 Individual Thermocouple Extension
piece while thermocouple cable is con- Cable
thermocouple connected to receptacle
nected to the power source.
TC1. If multiple thermocouples are desired, 4 Multiple Thermocouple Extension
either use individual thermocouple plugs or Turn Off power source. Cable
the thermocouple extension cable.
1 Power Source
To connect thermocouples to the power Align plug pin(s) with receptacle socket(s)
source, proceed as follows: 2 Thermocouple Receptacles and push plug into receptacle.
OM-271146 Page 23
5-15. Attaching Welded Thermocouples
. Do NOT weld thermocouples while connected to power source.
1. Attach thermocouples using a portable Thermocouple Attachment Unit (TAU). This unit spot welds thermocouple wire directly to the
workpiece. This method of thermocouple attachment ensures accurate temperature measurement.
2. Clean (file or grind) any loose scale or rust from the workpiece at the places where the wires will be attached.
3. Clean the location for the lead magnet to minimize resistance. Place the magnet as near to the thermocouple positions as possible.
4. Strip 1/4 in. of insulation from the thermocouple wires.
5. Set the output variable control of the TAU to about eighty percent (80%).
6. Grasp one of the stripped wires with the tip of the jaws of the application pliers.
. Don’t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit. This will cause
the thermocouple wire to fuse to the pliers, rather than the workpiece.
7. Press the end of the wire to the workpiece at ninety degrees to the surface, and maintain a firm pressure. Make sure the Thermocouple Attach-
ment Unit is charged and wait for the ready light to glow.
8. Press discharge button, and the wire should weld to the workpiece. There will be a sharp crack and a slight arc flash.
9. Repeat the process with the other wire, placing it approximately 1/4 in. away from the first wire. Attach a spare thermocouple, and support both
thermocouples approximately 18 in. back from the connection with a band or fiber tape.
10. Carefully bend the wire over at right angles. This brings the thermocouple wires out along or parallel to the workpiece. It also tests the strength
of the weld. If the weld shows signs of breaking, remove the wire, restrip the end, and repeat the process.
Strap Or Tape
Thermocouple
Wires
Tools Needed:
804 322-A
OM-271146 Page 24
5-16. Using Contact Thermocouple Sensors
1 Blanket
2 Contact Thermocouple Sensor
(See Product Literature Sheet)
1
2 The welded thermocouples discussed previously can be
used for preheating or stress relieving. Welded thermo-
couples are normally used in stress relieving applications
because of their accuracy and ability to withstand high
temperatures.
As an alternative, in preheating applications a contact

thermocouple sensor can be used. This eliminates the
Top View Do not place TC probe need to weld thermocouples and the sensor can be
Flat on part under transition under heating moved during the preheat process to check temperatures
blanket at other locations on the joint. (Contact thermocouple
center of coils sensors are limited to 500° F [260° C ].)
Side View
. If the contact thermocouple sensor is removed, the
temperature recorder (if used) will display a short
Flat Surface
duration of heat drop.
. Place flat surface of sensor
in contact with blanket. The contact thermocouple sensor can be plugged into the
thermocouple extension cable or a Type K 25 ft. armored
extension cable. One of these extensions is required for
each sensor.
In preheating applications, the sensor must be placed un-

der the induction coil. To be accurate, the sensor flat end
must be held against the heated surface. If liquid-cooled
or air-cooled coils overlap at any location in your installa-
tion, it is recommended that a second sensor be placed at
that location.
NOTICE − Failure to follow these recommendations could
cause heat damage in the blanket or coil.
Not this Temperatures at the weld joint can be checked with tem-
perature sensitive crayons to verify the preheat tempera-
ture.
Placing Contact Thermocouple Sensor
Place sensor between blanket and metal material. The
sensor must be flat and in firm contact with the material
Decouple blanket being heated. The tip of the sensor should be positioned
Control TC near edges under the center of the wires of the blanket anywhere
along the blanket length.
To prevent thermocouple sensor from pulling out of
Add additional TC position, contact TC sensor securing band 301 073 is
locations near edges available.
NOTICE − When using a contact thermocouple with air
cooled blankets, position is critical. If any part of the blan-
ket exceeds 400F (200C) for extended periods of time,
damage to the blanket will occur.
Additional sensors may be placed at the ends of the part
to protect from overheating. If a blanket is hanging off the
end of the part or goes over a cutout, insulation may be
added between the blanket and metal, slightly decoupling
the coil, which causes the area to receive less eddy
currents and generate less heat.
NOTICE − When heating next to a joint, control sensor
(TC#1) must be under the heating coil. A separate sensor
may be placed at the joint to monitor joint temperature.
When positioning blankets in vertical or overhead posi-
tions, ensure the non-insulated side of the blanket is able
to radiate heat. Do not cover blanket with insulation,
wood, etc. Trapping heat in the blanket may damage the
blanket.
273 097-A
5-17. Using Non−contact Temperature Sensors

It is important to locate non-contact temperature sensors so that they are measuring as close to the heat zone as possible to achieve consistent temper-
ature control of the system. The greater the distance between the heat zone and the area read by the sensor, the greater the temperature will fluctuate
around the target temperature.
The spot measurement location should be within two inches (50 mm) of the heat zone.
OM-271146 Page 25
SECTION 6 − COMPONENTS AND CONTROLS
6-1. Controls
3 4 5 6 7 10 9 8 11 18
16
17
2
15
14
19 13
12
803 995-B
. When a control panel button is pushed LED lights to indicate a system limit
condition.
14 Parameter Button
the yellow lamp lights to indicate ac- Use button to display real time power
tivation. 7 Heat On LED source operating parameters.
1 Power Switch LED lights to indicate the power source out- 15 Cooler Button
put is energized.
Use switch to turn power source On and Use button to turn cooler On and Off.
Off. 8 Stop Button
Use button to stop a heating process. 16 Increase Button
2 TC1−4 Temperature Display
Provides temperature display of thermo- 9 Hold Button Use button to increase values in set-up
couples 1 through 4. Use button to hold a heating process. screen.
3 Control Thermocouple LEDs 10 Run Button 17 Decrease Button
LEDs indicate which thermocouples (1−4) Use button to run a heating process. Use button to decrease value in program
are used to control the heating process. 11 Cursor Button screen.
4 Temperature Units LEDs Use button to move selection cursor in the 18 4 x 40 LCD Display
LEDs indicate units for temperature mea- 4 x 40 LCD display (item 18). Displays programming, runs status, pa-
surements (°F or ° C). 12 Program Button rameter, fault and limit conditions, and trou-
5 Fault LED Use button to program the process control. bleshooting guide.
LED lights to indicate a system fault 13 Run Status Button 19 Thermocouple Input Receptacles
condition.
Use button to display real time operating Use receptacles for type K thermocouple
6 Limit LED status. inputs.
OM-271146 Page 26
SECTION 7 − SETUP AND OPERATION
7-1. Safety Equipment
! Do not wear rings or watches
during operation.
1 2
Wear the following during
operation:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
sb3.1* 1/94
7-2. System Description

The ProHeat 35 Induction Heating Power Source is designed to function either as an air-cooled system or a liquid-cooled system. Depending on the
system type (including Air-cooled, Liquid-cooled, and Rolling Inductor), the power source is automatically configured to operate and provide an output
appropriate for the type of connected heating device.
A special identifier, embedded within the extension cable connector, provides the means for the power source to configure itself by recognizing the type
of extension cable(s) attached to its output connectors.
Designed to provide a single level of output (up to 35 kW), the ProHeat 35 power source has two panel mounted connectors that are connected in
parallel to the power source output. This design allows the system to operate with either a single output extension cable or two output extension cables.
If a single output extension cable is used, a protective plug (provided with the system) MUST be placed on the unused output connector or the system
will not operate. If two output extension cables are used, they both MUST be of the same type (either both air-cooled or both liquid-cooled) or the system
will not operate (in this case, the protective plug is not used). When two extension cables and heating devices are utilized on the system, the extension
cable lengths and heating devices MUST be identical (see Section 5-7).
The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal tempera-
tures reach or exceed specific set limits (see Section 10).
7-3. Important System Guidelines

NOTICE − When using multiple ProHeat systems on the same workpiece, keep the the coil(s) from each system at least 1 ft (30 cm) apart. The ProHeat
35 may be damaged if coils are placed closer together.
NOTICE − Some residual heating can occur in ferrous materials placed near the output cables. Moving the output cables away from the ferrous materi-
als could reduce inadvertent heating.
Non−ferrous materials can be used for fixturing depending on part temperature. Examples include glastic, pegboard, wood, PVC, and fiberglass. If
metallic materials need to be used, consider limited amounts of aluminum, brass, or copper.
7-4. Power Source/System Setup
kW
To view the System Setup screen, simultaneously press the Parameters V
A and Program buttons and the following screen will appear
Hz
on the display:
System Setup Screen 1
Deg Units...:>_F SYSTEM SETUP1

Tolerance...: ±25
Max Output..: 35 KW RI Clr Purge: 60s
Control Mode: Temp RI Init KW: 0.0KW
To change a setting:
S Press the Cursor button to move the cursor to the parameter to be changed.
S Press Increase or Decrease button to select desired set-up feature.
OM-271146 Page 27
Possible selections:
Degree Units: °F / °C
Tolerance: ±5 to 99 in °F (±3 to 55 in °C)
Control Mode: Temp / Remote / Time / Manual
Temperature Mode
S Initial kW value used in Rolling Inductor mode only
S Uses IR to control power
Time Mode
S Does not use Initial kW setting
S IR sensors can monitor temperature but not control power
Remote Mode
S Functions same as Manual Mode but from a remote
Manual Mode
S Initial kW value not used
Rolling Inductor Initial kW: 0.0−35.0 kW
Power Output: 1 to 35 kW
Rolling Inductor Cooler Purge Time: 30−240 seconds
Degree Units − Selection will drive the °F / °C indicator LEDs.

S The factory default is °F.
S Changing from °F to °C will convert stored program values: ramp temperature, soak temperature, ramp rate, and temperature tolerance.
Tolerance − The factory default is ±25 °F.
Control Mode − Either Temperature, Remote, or Power vs Time (Time), or Manual. For more details about methods of control, see Section 7-5.
S The factory default is temperature based control.
Rolling Inductor Initial kW − The factory default is 0.0. Max setting is dependant on Max Output setting.
Power Output − The factory default is 35 kW.
Rolling Inductor Cooler Purge Time − The factory default is 60 seconds.
kW
Simultaneously press the Parameters V
A and Program buttons a second time, and the following screen will appear on the display:
Hz
System Setup Screen 2
TC1,2 Type...:>IR4−20 SYSTEM SETUP2

IR Input Max.: 750 Trvl Detect..: On
IR Input Min.: 212 Trvl Speed...: IPM
Decouple Fault: On
Possible selections:
Input Type: K TC / IR 4−20 ma (TC 3−6 are fixed at K TC)
IR Input Max: Set the IR sensor’s (20 mA) equivalent value
Travel Detect: On / Off − Functions as an On / Off switch with air and liquid-cooled cables. See Table 7-2 for information on functionality with
Rolling Inductor.
IR Input Min: Set the IR sensor’s (4 mA) equivalent value
Travel Speed IPM / CPM (inches per minute/centimeters per minute)
Decouple Fault: On / Off
OM-271146 Page 28
Turning off the Decouple Fault allows the system to run with poorly coupled coils. This feature is only available when using liquid cooled cables.
A message will display each time the ProHeat is turned on to remind that the circuit is turned off.
F73: Decoupled/Open Coil

Fault Disabled for
Liquid Cooled Cables Only
Press (−) to Acknowledge
Press the Decrease button on the front panel to acknowledge the message.
If using a remote On/Off switch, cycling from Off to On 2 times within 3 seconds will also acknowledge the message.
Display Contrast − press and hold the cursor and press the Increase button to darken, or press the Decrease button to lighten the
contrast.
. All parameters in System Setup are considered global, and any changes to the system set-up parameters will apply to all programs.
. The option to turn backlight on/off was removed at software revision 1.26. Backlight is now always on.
7-4-1. Factory Defaults
To reset the system back to factory default settings, turn off the power source, and wait until the display goes blank. Turn on the power source. When
the display lights, press and hold the Increase and Decrease buttons. A message will display Press Program to reset factory
defaults. Release the Increase and Decrease buttons, and press the Program button.
7-5. Programming
Programming allows the operator to setup a program for a particular heating process. The selections available are Temperature, Remote, Manual, or
Power vs Time (Time).
7-5-1. Temperature-Based Control
Temperature-based control operates the system and controls the heating process based on temperature feedback from thermocouple inputs. Ther-
mocouples must be used for this mode of operation or the system will not operate. Within the temperature-based mode there are four different
processes available as follows: Preheat, Bakeout, PWHT (Post-Weld Heat Treat), and Custom Program.
Press the Program button to access the programming mode. Use the cursor button to move the cursor to the desired temperature-based process,
then press the Program button again to select the process.
7-5-1-1. Preheat
The preheat process is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time.
When this process is selected, the following screen will appear on the LCD display:
Preheat Screen
Mode.......: Preheat
Control TC.: 1
Temperature: 400
Soak Time..: 01:00:00
OM-271146 Page 29
The default position of the cursor is next to Control TC. Press the Increase or Decrease button to select the number of control
thermocouples to be used for the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2
thru TC4 can be used for controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display
illuminates.
Use the Cursor button to move the cursor to the desired selection (Temperature or Soak Time), and press the Increase or
Decrease button to change the value to the desired setting.
. The minimum and maximum temperature settings for preheat are 0 and 1450 F (−18 and 788 C). The minimum and maximum soak times are
0 and 100 hours or extended. When the system is utilizing air-cooled blankets, the maximum temperature setting is 400 F (204 C). If the program
setting is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is pressed:
Maximum Temperature Message Screen
Cannot enter Run mode

Programmed temperature settings
exceed air cooled limits
(400 _F, 204 _C)
7-5-1-2. Bake-Out
The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from bake-out if desired. When this
process is selected, the following screen appears on the display:
Bake-Out Screen
Mode......: Bake−Out
Control TC:>1
Soak Temp.: 600 Soak Time: 01:00:00
Cool Temp.: 200 Cool Rate: 600 _/Hr
illuminates.
Use the Cursor button to move the cursor to the desired selection (Soak Temperature, Soak Time, Cool Temperature, or Cool Rate), and
press the Increase or Decrease button to change the value to the desired setting.
. The minimum and maximum soak and cool temperature settings for bake-out are 0 and 1450 F(−18 and 788 C). The minimum and maximum
soak times are 0 and 100 hours or extended. The minimum and maximum cool rates are 10 and 9999 /hr. When the system is utilizing air-cooled
blankets, the maximum temperature setting is 400 F(204 C). If the program setting is above 400 F (204 C), the following screen will appear
on the LCD display when the Run button is pressed:
OM-271146 Page 30

(400 _F, 204 _C)
7-5-1-3. PWHT (Post-Weld Heat Treat)

The post-weld heat treat process allows the operator to program a post-weld heat treat where ramp temperature (on increase and decrease) and
ramp rates are the same. When this process is selected, the following screen appears on the display:
PWHT Screen
Mode......: PWHT
Control TC:>1,2
Ramp Temp.: 200 Ramp Rate: 600 _/Hr
Soak Temp.: 400 Soak Time: 01:00:00
illuminates.
Use the Cursor button to move the cursor to the desired selection (Ramp Temperature, Ramp Rate, Soak Temperature, or Soak Time),
and press the Increase or Decrease button to change the value to the desired setting.
Soak Temp Soak Time
Ramp Rate
Ramp Temp
Figure 6-1. Soak Parameters
. The minimum and maximum ramp temperature settings for PWHT are 0 and 1450 F (−18 and 788 C). The minimum and maximum ramp rates
are 10 and 9999 F/hr (6 and 5555 C/hr). The minimum and maximum soak temperatures are 0 and 1450 F (−18 and 788 C). The minimum
and maximum soak times are 0 and 100 hours or extended. When the system is utilizing air-cooled blankets, the maximum temperature setting
is 400 F (204 C). If the program setting is above 400 F (204 C), the following screen will appear on the LCD display when the Run button is
pressed.
OM-271146 Page 31

(400 _F, 204 _C)

(400 _F, 204 _C)
7-5-1-4. PWHT Operation

When a PWHT cycle is started, you may monitor where you are at in the cycle by selecting the Status Screen. From there you can determine what mode
you are in, what the heat controller’s current calculated target temperature is, and see the Soak Timer Countdown.
When using a single TC in the control loop, it is in control of the entire cycle. When using 2 - 4 control TCs, the ProHeat 35’s heat control has the following
characteristics:
• When ramping up from the Ramp temperature to the Soak temperature, the TC with the highest temperature is the TC in control.
• In many applications, the temperature of all the control TCs stay close together throughout the entire cycle, within the the programmed tolerance
band (default is +/- 25°F) of the set point. In these typical cases, the unit continues from the Ramp cycle into the Soak cycle, and the Soak countdown
timer starts.
When at the Soak temperature set point, all control TC temperatures must be within the tolerance band before the Soak countdown timer will start. If
all TCs are not within tolerance, heating continues until the hottest TC reaches the set point plus the tolerance band. The unit does not allow output
above the set point plus the tolerance band. If all temperatures are not within the tolerance band, you have three options :
1. Allow time for the heat to conduct around and through the material. This may allow the area with the coolest TC to heat up above the minimum
(set point − tolerance) allowing the Soak cycle to continue.
2. Manipulate the coil over the hot area, allowing that area to cool down. To accomplish this, you must stop the cycle, spread coil turns apart,
remove coil turns, or pull the coil away (decoupling the coil) only over the area where the hot control TC is located. As a result, the output power will
increase slightly allowing the cooler areas to heat up.
3. Change the tolerance band. To accomplish this, stop the cycle, enter the Setup screen and increase the tolerance setting. Resume the cycle.
Certain codes such as ASME B31.1 and B31.3, do not allow tolerance settings over +/- 25°F, so be sure to check the code, or check with your
engineers to see if this is allowed.
• When ramping down from the Soak temperature to the Ramp temperature, the TC with lowest temperature is the TC in control.
• If the part cannot be heated at the requested rate (i.e. because of part mass, coil setup, etc.) the target temp displayed by the heat control will never
exceed a 10°F difference from the control TC.
OM-271146 Page 32
7-5-1-5. Custom Program
In Custom Program, the operator can create a custom program with multiple steps or nonsymmetrical heat treat programs where the heating and
cooling rates and temperatures are different. When this process is selected, the following screen appears on the display:
. This is the screen for initial use of the system. Subsequent use of custom program will revert to the last program used.
Custom Program Screen
Mode.......: Custom Program

Segment....: >1
Type.......: End
Control TC.: 1
The default position of the cursor is next to Segment. Press the Increase or Decrease button to increase or decrease the seg-
ment number, unless the segment type is End. In this case, the segment number will advance to segment 1.
Use the Cursor button to move the cursor to the desired selection (Type or Control TC), and press the Increase or Decrease
button to change the value to the desired setting. When the cursor is moved to the Type selection, pressing the Increase or
Decrease button changes the segment type to Step, Ramp, Soak, or End. The functions of each segment type are as follows:
S Step increases the temperature in the part at full-programmed power. A maximum temperature of 1450° F (788° C) can be programmed.
S Ramp increases or decreases the temperature in the part at a controlled rate in degrees per hour. A maximum temperature of 1450° F (788°
C) and a maximum rate of 9999° F/hr (5555° C/hr) can be programmed.
S Soak will hold the temperature for a programmed time. The minimum and maximum soak times are 0 and 100 hours or extended.
S End is programmed to indicate the completion of the cycle and termination of output power.
Step Function
When type is set to Step, the following screen appears on the display:

Segment....: 1
Type.......:>Step
Temperature: 600
Use the Cursor button to move the cursor to the Temperature position and the initial temperature can be adjusted using the Increase
or Decrease button.
Pressing the Cursor button again automatically advances the program to the next segment number.
OM-271146 Page 33
Ramp Function
When type is set to Ramp, the following screen appears on the display:

Segment....: 1
Type.......: Ramp
Temperature: 600 Ramp Rate: 600 _/Hr
Use the Cursor button to move the cursor to the Temperature or Ramp Rate position and use the Increase or Decrease
button to set the desired value.
When the cursor is in the Ramp Rate position, pressing the Cursor button again automatically advances the program to the next segment
number.
Soak Function
When type is set to Soak, the following screen appears on the display:

Segment....: 1
Type.......:>Soak
Soak Time..: 00:01:00
Use the Cursor button to move the cursor to the Soak Time position and use the Increase or Decrease button to set the
desired value.
When the cursor is in the Soak Time position, pressing the Cursor button again automatically advances the program to the next segment
number.
End Function
When type is set to End, the following screen appears on the display:

Segment....:> 2
Type.......: End
Control TC.: 1
OM-271146 Page 34
The only changeable parameter in the End segment is selecting the number of thermocouples. Use the Cursor button to move the cursor
to the Control TC position. Press the Increase or Decrease button to select the number of control thermocouples to be used for
the program. Selections are as follows: 1, 1,2, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple. TC2 thru TC4 can be used for
controlling or monitoring. When a thermocouple is selected as control, the LED adjacent to the seven-segment display illuminates.
A custom program can contain up to 10 segments. To view Program parameters, position the cursor at segment and use the Increase or
Decrease button to advance through the segment numbers until the End segment. When a segment number is changed, appropriate
segment parameter information appears on the display.
Typical 5-Segment Custom Program

Segment....: 1
Type.......:>Step
Temperature: 600
Temperature increases to 600 degrees at full-programmed power.

Segment....: 2
Type.......: Ramp
Temperature:>1250 Ramp Rate: 600 _/Hr
Controlled heating to 1250 degrees F at a ramp of 600 degrees per hour.

Segment....: 3
Type.......: Soak
Soak Time..:>01:00:00
Soak at 1250 degrees F for a period of 1 hour.

Segment....: 4
Type.......:>Ramp
Temperature: 600 Ramp Rate: 600 _/Hr
Controlled cooling to 600 degrees F at a rate of 600 degrees per hour.
OM-271146 Page 35
Segment....: 5
Type.......: End
Control TC.: 1
End segment ends the heat treat cycle. Controller is programmed to control the process using four thermocouples.
7-5-2. Remote Control

Remote Control operates the system from a remote device which energizes or de−energizes output as well as setting the desired output power level
as a function of the maximum output power setting in the system setup screen. The run button on the front of the ProHeat 35 is disabled in remote
mode.
If Remote was selected as the control mode in the system setup screen, the following screen appears for programming:
Mode....: Remote Power..: 0.0 KW

Run Time:>00:03:00 Current: 0 A
Voltage: 0 V
Frequency: 4.5 KHz
Time is the only parameter that can be set. The values are 0 − 99:59:59 or extended.
. The Run button on the front of the power source is disabled in this mode. Use remote device to toggle output On or off.
7-5-3. Power vs Time Control
Power vs Time control operates the system and controls the heating process based on programmed time and power. Power increases over a pro-
grammed amount of time.
Press the Program button to access the programming mode. Use the cursor button to move the cursor between Mode, Segment, Type, Power, and
Time.
Mode...: Timed
Segment: 1
Type...:>Power Level
Power..: 0.0 KW Time: 00:00:00
The default position of the cursor is next to Program. Press the Increase or Decrease button.
Use the Cursor button to move the cursor to the desired selection, and press the Increase or Decrease button to
change the value to the desired setting.

Possible selections Timed:
Segment: 1 − 10
Type: Power Level, Slope, End
Power: 0.0 − 35 Time: 00:00:00 − 99:59:59 or extended
OM-271146 Page 36
7-5-4. Manual Control
Manual control allows programming of a specific power level for a specific period of time. When this process is selected, the following screen appears
on the display:
Manual Program Screen
Mode....: Manual Power..: 0.0 KW

Command.: 0.0 KW Current: 0 A
Run Time: 00:03:00 Voltage: 0 V
Frequency: 4.5 KHz
The only programmable selections are Command power and Run Time. Command can be adjusted to deliver up to 35 KW (based on maximum
power selected in the set-up screen) for a period of up to 99 hours, 59 minutes, 59 seconds.
Power source operating power, current, voltage, and frequency are shown on the right-hand side of the display.
To reset the system back to factory default settings, turn off the power source, and wait until the display goes blank. Turn on the power source. When
the display lights, press and hold the Increase and Decrease buttons. A message will display Press Program to reset factory
defaults. Release the Increase and Decrease buttons, and press the Program button.
7-5-5. Rolling Inductor—Manual Or Temperature Control Mode

NOTICE − When using a Rolling Inductor, infrared temperature measurement and travel detection are highly recommended. The Rolling Inductor
induces up to 20 kW into a small area, which can quickly heat a part to over 600 F (315 C) if it is not moving fast enough. This can damage the
inductor or part. Using the travel detector, the system reduces output as travel speed decreases and disables output when travel stops.
. The travel detector is a sensitive instrument that can measure travel speeds down to one IPM. Once the part travel is stopped, there is a three
second delay before output can be re-energized.
Vibrations that are present for more than three seconds from sources such as fork lift traffic, trains, grinding, and handling the part, can trigger
the sensor, and energize the output.
Always press Stop on the ProHeat front panel when part travel is stopped, to prevent inadvertent heating of the part.
Travel Detection
The Travel Detector can be mounted on the left or right side of the Rolling Inductor. It can also be mounted off of the inductor in a location that
provides a similar travel speed as that of the inductor. A bracket of 3.75 inches long by 2.5 inches wide (96 by 64 mm) will allow for mounting of the
Travel Detector.
. Connect Rolling Inductor(s) to power source before turning power on.
OM-271146 Page 37
kW
To view the System Setup screen, simultaneously press the Parameters V
A and Program buttons and the following screen will
Hz
appear on the display:
S Press Cursor button to move cursor to the parameter to change. Press Increase or Decrease button to set
parameters.
SYSTEM SETUP SCREEN 1
Deg Units...:>°F SYSTEM SETUP1

Tolerance...: ±25
Max Output..: 35 KW RI Clr Purge: 60S
Control Mode: Temp RI Init KW: 0.0KW
Set Deg Units to F or C as required.

Set Tolerance value if required.
Set Control Mode to Manual or Temp as required.
Set Rolling Inductor Initial kW to a value between 0.0 and 35.0 kW
S The Rolling Inductor Initial kW can be increased when working on larger mass parts. It is recommended that the first part is heated with
the kW set to a low value. Observe the maximum kW level that the heat cycle achieves and then set the starting kW to that value or less.
S Max Output kW can be reduced on smaller mass parts to minimize heat input.
Rolling Inductor Cooler Purge Time: 30−240 seconds
S The default Rolling Inductor Cooler Purge Time is set to 60 seconds for applications using the 60-foot inductor cables. This can be set
down to 30 seconds for the standard Rolling Inductor with 30-foot cables. The ProHeat automatically doubles the time when two Rolling Inductors
are connected.
kW
Simultaneously press the Parameters V
A and Program buttons a second time, and the following screen will appear on the display:
Hz
SYSTEM SETUP SCREEN 2
TC1,2 Type...:>IR4−20 SYSTEM SETUP2

IR Input Max.: 750 Trvl Detect..: On
IR Input Min.: 212 Trvl Speed...: IPM
Decouple Fault: On
Set Trvl Detect to On if using travel detection.

Travel detection is recommended for all Rolling Inductor applications. It assists in maintaining an even heat input to the part and regulates output
power based on travel speed in Temp mode.
Set Trvl Speed units as needed.
. IPM = Inches Per Minute:

PI = 3.14159 Direction
r = Radius (distance from center of rotating part to travel de- of r
tect wheel) travel
Direction
s = Seconds per rotation. of r
IPM = (2 * PI * r * 60) / s travel
Example: For a 24 in. diameter pipe, the radius = 12 in. If it

takes 45 seconds to make one complete rotation, the formu-
la would be:
IPM = (2 * 3.14159 * 12 * 60) / 45
IPM = (4523.9) / 45
IPM = 100.5
. IPM information can be seen on the Run Status menu while Flange
Pipe
heating.
OM-271146 Page 38
Press Program button once to enter the Rolling Inductor Program screen.
The screen should look as shown below.
Rolling Inductor Program Screen

Mode....: Manual Power…: 0.0 KW
Command.: >0.0 KW Current: 0 A
Run Time: 00:03:00 Voltage: 0 V
Frequency: 4.5 kHz
Plug one end of the thermocouple extension cable into TC5 on the power source and the other end into the back of the Rolling Inductor.
If running two Rolling Inductors on the same power source, connect a second thermocouple extension cable from the second Rolling Inductor to
TC6 on the power source.
. Workpieces should be the same size and material when using two Rolling Inductors on one power source.
NOTICE − TC5 and TC6 connect to the Rolling Inductor internal thermocouple which monitors internal Rolling Inductor core temperatures. Meaure
workpiece temperature with temperature crayons, infrared sensor, or contact thermocouples within two inches of the Rolling Inductor.
7-6. Run Status

Run status allows the operator to check status of a program during in-process heating. Depending on the control mode (Temperature or Manual) and
the temperature based mode (Preheat, Bake-Out, PWHT, or Custom), different style screens appear on the display. Run status is for monitoring pur-
poses only and has no selectable or changeable parameters.
7-6-1. Temperature Based Control

7-6-1-1. Preheat, Bake-Out And PWHT Run Status Screen
Run Status Screen
Mode.......: Preheat TC5: 77

Target Temp: −−−− TC6: 77
Countdown..: −−:−−:−− TvlIPM(Off): 0
Status.....: Stopped
Mode displays the programming mode (Preheat, Bake-Out, PWHT, or Custom Program). During active operation, Target Temp shows the target
temperature based on the specific program, Countdown shows the time remaining in a soak segment, and Status shows the program segment type
(step, soak, ramp, hold, or stopped). TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.
7-6-1-2. Custom Program (Not Applicable With Rolling Inductor)

Run Status Screen
Mode.......: Custom Program TC5: 77

Target Temp: −−−− TC6: 77
Countdown..: −−:−−:−− Segment: 1
Status.....: Stopped
During active operation, Target Temp shows the target temperature based on the active segment, Countdown shows the time remaining in a soak
segment, and Status shows the program segment type (step, soak, ramp, hold, or stopped) of the active segment and the active segment number.
TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitoring purposes only.
OM-271146 Page 39
7-6-2. Manual Control
Run Status Screen
Mode.....: Manual TC5: 77

Power....: 0.0 KW TC6: 77
Countdown: −−:−−:−− TvlIPM(Off): 0
Status...: Stopped
During active operation, Power shows the actual power delivered from the power source, Countdown shows the time remaining in the heating cycle,
and Status indicates if the system is running or stopped. TC5 and TC6 display the temperature of thermocouples 5 and 6. This screen is for monitor-
ing purposes only.
. No changes can be made to the run status screen, and the Cursor, Increase and Decrease buttons are not functional.
7-6-3. Remote Control

Run Status Screen
Mode.....: Remote TC5: 77
Power....: 0.0 KW TC6: 77
Countdown: 00:00:00 TvlIPM (Off): 0
Status...: Stopped
During active operation, Power shows the actual power delivered from the power source, Countdown shows the time remaining of the heating cycle,
and Status indicates if the system is running or stopped. This screen is for monitoring purposes only.
. No changes can be made to the run status screen, and the Cursor, Increase and Decrease buttons are not functional.
7-6-4. Power vs Time Control

Run Status Screen
Mode...: Power vs Time TC5: OPEN
Segment: 1 TC6: OPEN
Type...: −−:−−:−− TvlIPM(Off): 0
Power..: 0.0 KW Type: End
Mode displays the control mode. Also displayed are the present program segment, Segment type, current power level and remaining time of the
current segment.
7-7. Parameters
During active operation, the Parameters screen allows the operator to monitor the power source output operating parameters. These parameters in-
clude output power, output amperage, output voltage, and output frequency. In addition, temperatures of thermocouples TC5 and TC6 are also
displayed. The Parameters screen is for monitoring purposes only and has no selectable or changeable parameters.
OM-271146 Page 40
Parameters Screen
Power....: 0.2 KW TC5: OPEN

Current..: 20 A TC6: OPEN
Voltage..: 52 V Power Level
Frequency: 11.7 KHz Countdown: 00:14:36
7-8. Cooler
The Cooler button is used to turn the cooler On or Off on systems using liquid-cooled output cables. Systems using liquid-cooled output
cables will not deliver output unless the cooler is On. If the cooler is not started prior to initiating a heating cycle, the system will automatically start the
cooler when the Run button is pressed. Pressing the Stop button does not shut off the cooler. The cooler must be shut off separately
by pressing the Cooler button.
When power source output is energized, the cooler cannot be turned off. If the Cooler button is pressed while output is energized, the following
screen will appear on the display:
Cooler Message Screen
Cooler cannot be turned off

while output is on
. The Cooler button is inactive when no cooler is detected and no liquid-cooled output cable is attached.
. When a Rolling Inductor is connected to the power source, the cooler will purge for time set in SYSTEM SETUP1 RI Clr Purge, which is typically
30−60 seconds per rolling inductor before allowing output to be enabled.
7-9. Real-Time Operation

Each time the unit is first turned On it initiates a system check routine that includes verification of communication between circuit boards and checking
for output isolation faults. During this check routine, all displays and LEDs illuminate and the following screen appears on the display:
Power Up Message Screen
ProHeat
Firmware Revision X.XX
Copyright (c) 2005 − 2015
Miller Electric Mfg. Co.
X.XX indicates the firmware revision number installed in the unit.
If an error is detected during the check routine, the system fault LED illuminates and an error message screen appears on the display (see Section
10-5).
When the check routine is completed successfully, the operator interface defaults to the following:
OM-271146 Page 41
S The Stop button indicator LED illuminates to indicate no heating cycle is in process.
S The temperature displays indicate actual temperature from the TC’s (thermocouples). If no thermocouples are connected, the displays
indicate OPEN.
S Control LEDs illuminate to indicate the number of control TC’s in the last program.
S The appropriate degree units (°F or °C) light illuminates.
S The display defaults to the Run Status screen from the last program used and the Run Status button indicator LED illuminates.
S If no fault or limit conditions are present, system status lights are not illuminated.
Once set up is complete for the desired program procedure (see Section 7-4), pressing the Run button will initiate a heating cycle. When a
program run is initiated, the Run button yellow indicator LED illuminates and the Heat On blue indicator LED illuminates to indicate output is
present to the coil. The cycle will continue until the end of the program is reached or the Stop button is pressed.
The system has a hold function that will maintain a temperature or hold the soak time of any active temperature controlled program. Pressing the Hold
button will only activate the hold function while in the run mode. If the system is not in the run mode, the following screen will appear on the display:
Hold Message Screen
Must be running to enter Hold mode
In addition, when running in Manual operating mode, the Hold button is not functional. If the system is running in Manual operating mode,
pressing the Hold button will cause the following screen to appear on the display:
Hold Message Screen
Hold mode not available when

temperature control is not active
Pressing the Hold button will activate the hold function while running a temperature controlled program. While in the hold mode, the parame-
ters for the program in process can be modified. The cycle will continue after pressing the Run button. A change of program parameters during
the hold will not change the original program. The original program parameters are maintained for the next heating cycle.
OM-271146 Page 42
To make changes to a program while in run mode, press the Hold button and the yellow indicator LED will illuminate, and the Run button
yellow indicator LED will turn off. When in hold, the system will maintain the actual temperature of the hottest thermocouple while the program is being changed.
S Press the Program button and the yellow indicator LED will illuminate. The display will change to show the current mode of opera-
tion or the current segment of a Custom Program.
S Use the Cursor button to move the cursor to the parameter that will be changed.
S Press the Increase or Decrease button to make desired changes.
S Press the Run button to resume program operation and the yellow indicator LED will illuminate, and the Hold button
yellow indicator LED will turn off.

Any program parameter (temperatures, rates, times, or number of TC’s) can be changed while in hold. In a custom based program, any segment number can
be changed; however, if the operation of a segment has already been completed in a program, the change to that segment will not affect the program function.
S Press the Stop button to end the program.
OM-271146 Page 43
7-10. System Operating Characteristics
The power source delivers a high-frequency alternating current output that energizes the coil creating the magnetic field used to heat the workpiece.
The power source output characteristics are a function of the configuration, type and number of coils used as shown in the following table:
Table 7-1. Power Source Output Characteristics

Output Type Maximum Amperage Maximum Voltage Frequency Range
250 A per output for 15 minutes.
After 15 minutes, power steps
down to limit current to 150 am- 700 V 5 − 25.7 kHz
Air Cooled Single and Dual peres per output for continuous
operation.
See Note 1 700 V 25.7 − 30 kHz
350 A 700 V 5 − 20 kHz
Single Liquid Cooled
See Note 2 700 V 20 − 30 kHz
350 A per output/700 A total 700 V 5 − 20 kHz
Dual Liquid Cooled
See Note 2 700 V 20 − 30 kHz
300
Air Cooled Output
. Note 1: In the frequency range
of 25.7 to 30 KHz, the maxi-
mum output amperage de-
250 creases linearly from 250 down
to 175 amperes per output. Re-
gardless of frequency, after 15
Max Amperage Per Output
minutes the maximum output is

200
reduced to 150 amperes per
output.
150
100
50
0
5 25.7 30
Frequency (KHz)
400 . Note 2: In the frequency range

Liquid Cooled Output of 20 to 30 KHz, the maximum
output decreases linearly from
350
350 down to 175 amperes per
output.
300
Max Amperage Per Output
250
200
150
100
50
0
5 20 30
Frequency (KHz)
OM-271146 Page 44
Table 7-2. Rolling Inductor Output Characteristics
Output Type Maximum Amperage
Single Rolling Inductor 300 A
300 A Per Output
Dual Rolling Inductor The system maximum power is 35 kW, so each output will have approximately 17.5 kW, which uses
less than 300 A
The Rolling Inductor can be operated

Max Power Output Vs. Heating Time with Manual Control, Temperature
Control only, or Temperature Control
With Initial Power Setting = 0 kW with Travel Detection.
Manual Control provides Max Output
35.0 power, as set in SYSTEM SETUP1
screen, at the start of the cycle.
30.0 Temperature Control provides output
power starting at the RI Init KW value,
25.0 as set in SYSTEM SETUP1 screen, at
the start of the cycle. The curves
illustrated increase as shown directly
20.0 from the RI Init KW value.
KW
Above 15 IPM The rate of power output is limited at

15.0 travel speeds below 15 in./min (38cm/
min) or when no travel detection is
Below 15 IPM or no present to help prevent temperature
10.0 overshoot in the part.
Travel Detection
With travel detection and travel speeds
5.0 above 15 in./min (38cm/min), the rate
of power output is increased. In either
0.0 case the maximum power output is
limited to 300 amps per output, which
00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 is about 20 kW with one Rolling Induc-
Minutes tor and 35 kW with two Rolling Induc-
tors.
The graph illustrates the rate at which
output power is increased with heating
time.
Max Power Output vs. Travel Speed With travel detection, the maximum
(For Temp Or Manual Control With Travel Detect) power output is determined by the
travel speed, as illustrated.
35
30
25
Max KW
20
Max KW
15
10
0
0 5 10 15 20 25 30
Travel Speed IPM
OM-271146 Page 45
SECTION 8 − MAINTENANCE
8-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
Daily 2 1
n Visually inspect condi-

tion of cords and cables. l
Damaged cords or cables.
Every Section 5-7,
3 2 1 2 1
5-12
Months
l Damaged or Unreadable ~ Output Connector Con- ~ Isolation Protection Lead ~ Operator Interface Over-
Labels tacts Receptacle lay
2 1
n Integrity Of Protective nlCracked Cables

Plug, Replace If Necessary
Every Section
6 10-10
Months
~ Inside Unit
Every Sections
Year 8-2, 8-3
n Verify Unit Calibration
OM-271146 Page 46
8-2. Calibration Verification Equipment
2 3 4 5 6
1
1 Thermocoupler Calibrator yellow to positive when wiring connectors. Suggested meters are Agilent Multimeter
Suggested calibrator from Fluke item 714 3 Type K 2-Pin Male Connector or Hewlett Packard Multimeter Model
or equivalent. 34401A or equivalent. DVM must be able
Suggested connector from Newport item
to read to three decimal places (0.000).
2 Type K Mini Connector OST−K−M or equivalent
Suggested connector from Fluke item 4 Calibration Label 6 Interconnecting Cable
80CK−M or equivalent. Suggested label from Q−CEES item MILLER Part No. 300168 can be used to
A length of type K thermocouple wire is QCC306BU or equivalent. connect the Recorder to the DC power
required. Connect red to negative and 5 Precision Digital Voltmeter (DVM) supply.
8-3. Calibration Verification Procedure

Calibration verification should be done every year. Use appropriate Certificate of Calibration to record calibration information. A spreadsheet could also
be used to record the information.
8-3-1. Initial Set Up

1. Power switch off
2. Have qualified person connect primary power to ProHeat 35.
3. Turn ProHeat 35 power switch on.
4. Press and hold the Program button, then press Parameters to enter setup mode.
5. Press Cursor button 4 times to get to Control Mode line.
6. Press the Decrease button to change to Manual, if necessary.
7. Press the Run Status button. (TC5 and TC6 will show in upper right-hand corner of display)
8. Let unit idle for a minimum of 15 minutes before checking calibration.
9. Turn on Fluke 714 Thermocouple Calibrator and Precision DVM. Leave them on for a minimum of 15 minutes before checking calibration.
10. Verify TC1 and TC2 are set to K-Type. See Section 7-4 for detailed instructions.
8-3-2. TC Input/Output Check

1. Connect precision DVM (DC Volts set to display in thousandths) to RC9. This is the top connector located on the back of the ProHeat 35. Red
lead to pin 1 and black to pin 5.
2. Set TC calibrator to 382.0 °F or 194.5 °C. Connect to TC1 input jack on front of ProHeat.
3. Verify TC display value of (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F) or (±3.3°C). DVM reads 2.787 VDC (±0.038) (2.749 – 2.825).
4. Enter DVM values into calibration certificate If you are creating your own spreadsheet use the following calculation.
The voltage to temperature calculation is:

(DC Volts Out x 155) − 50 = °F
(DC Volts Out x 86.1) − 45.4 = °C
5. Repeat steps 1.−4. for TC2 – TC6 input jacks.
For TC2 move red precision DVM lead to RC9 pin 2.

Note: TC5 and TC6 will show in upper right-hand corner of display.
6. Repeat steps 1.−5. with TC calibrator set to 882.0 °F or 472.2 °C, verify TC display value (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F)
or (±3.3°C). DVM reads 6.013 VDC (±0.038) (5.975 – 6.041).
7. Repeat steps 1.−5. with TC calibrator set to 1382.0 °F or 750 °C, verify TC display value (±3°F) or (±2°C). RC9 output has a tolerance of (±6°F)
or (±3.3°C). DVM reads 9.239 VDC (±0.038) (9.201 – 9.277).
OM-271146 Page 47
8-3-3. Finishing Procedure
1. If ProHeat 35 was set for Temp in Control Mode follow steps 8-3-1, steps 4.−6. to change it back to Temp.
2. Turn ProHeat 35 power switch off.
3. Have qualified person disconnect primary power.
4. Remove precision DVM and TC calibrator.
5. Complete calibration label & place it on unit directly above TC1 display.
I.D. No. (TC board serial number) Be sure the serial number matches the board in the machine.
By (your initials) Date (today’s date)
Due (date 1 year from today)
6. Print a copy of the certificate to send with the ProHeat 35.
7. If entering data in a spreadsheet, save data.
Notes
OM-271146 Page 48
Com pany Nam e
Street
PO Box
City, State, Zip Code
CERTIFICATE OF CALIBRATION VERIFICATION
TCI Serial Number: Calibration Date:

Certified by: Re−Calibration Date:
Company name does hereby certify the above instrument was calibrated against standards
maintained by Company name and meets or exceeds all published specifications.
The accuracy of these standards is directly traceable to the National Institute of Standards and Technology.
PRIMARY STANDARD PRIMARY STANDARD PRIMARY STANDARD

382 (°F) 882 (°F) 1382 (°F)
Voltage Equivalent Voltage Equivalent Voltage Equivalent
Out (V) Temp (°F) Out (V) Temp (°F) Out (V) Temp (°F)
CHANNEL 1
CHANNEL 2
CHANNEL 3
CHANNEL 4
CHANNEL 5
CHANNEL 6
Instrumentation Used:
Thermocouple Calibrator: Serial Number:

Calibrated Multimeter: Serial Number:
OM-271146 Page 49
A−232171−C 09/09/16
Com pany Nam e
Street
PO Box
City, State, Zip Code
OM-271146 Page 50
CERTIFICATE OF CALIBRATION VERIFICATION
TCI Serial Number: Calibration Date:

Certified by: Re−Calibration Date:
Company name does hereby certify the above instrument was calibrated against standards
maintained by Company name and meets or exceeds all published specifications.
The accuracy of these standards is directly traceable to the National Institute of Standards and Technology.
P R IM AR Y S T AN D AR D P R IM AR Y S T AN D AR D P R IM AR Y S T AN D AR D
1 94 (°C ) 4 7 2 (°C ) 75 0 (°C )
V o lta g e E q u iv a le n t V o ltag e E q u iv a le n t V o ltag e E q u iva len t
O u t (V ) T em p (°C ) O u t (V ) T e m p (°C ) O u t (V ) T e m p (°C )
C H AN N E L 1
C H AN N E L 2
C H AN N E L 3
C H AN N E L 4
C H AN N E L 5
C H AN N E L 6
Instrumentation Used:
Thermocouple Calibrator: Serial Number:

Calibrated Multimeter: Serial Number:
A−232171−C 09/09/16
SECTION 9 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
9-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
9-2. Servicing Hazards
The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
Only qualified persons should service, test, maintain, and re- D Use proper static-proof bags and boxes to
pair this unit. store, move, or ship PC boards.
During servicing, keep everybody, especially children, away.

FIRE OR EXPLOSION hazard.
ELECTRIC SHOCK can kill. D Do not place unit on, over, or near combustible
surfaces.
D Do not touch live electrical parts. D Do not service unit near flammables.
D Turn Off induction heating power source and
disconnect and lockout input power using line
disconnect switch, circuit breakers, or by removing plug from recep- FLYING METAL or DIRT can injure eyes.
tacle, or stop engine before servicing unless the procedure specifi-
cally requires an energized unit. D Wear safety glasses with side shields or face
shield during servicing.
D Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground. D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job. INDUCTION HEATING can burn.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free. D Do not touch hot parts bare handed.
D Allow cooling period before handling parts on
D Disconnect input power conductors from deenergized supply line
equipment.
BEFORE moving an induction heating power source.
D Do not touch or handle induction head/coil during operation.
SIGNIFICANT DC VOLTAGE exists in inverter D Keep metal jewelry and other metal personal items away from
power sources AFTER removal of input power. head/coil during operation.
D To handle hot parts, use proper tools and/or wear heavy, insu-
D Turn Off inverter, disconnect input power, and discharge input
lated welding gloves and clothing to prevent burns.
capacitors according to instructions in Troubleshooting Section be-
fore touching any parts.
EXPLODING PARTS can injure.

ARC FLASH can kill.
D Failed parts can explode or cause other parts to
Arc flash is the rapid and violent release of energy that explode when power is applied to inverters.
occurs when electric current leaves its intended path D Always wear a face shield and long sleeves
and arcs to other conductors or to ground. Arc flash
can be caused by equipment failure (faulty insulation, when servicing inverters.
corrosion, dust) improper installation, human error (improper tool
placement), and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk. SHOCK HAZARD from testing.
D Do not work on energized equipment unless an assessment of D Turn Off induction heating power source be-
arc flash risk from the electrical supply circuit has been conducted fore making or changing meter lead connec-
by a qualified person and you have been trained in safe work prac- tions.
tices by your employer. D Use at least one meter lead that has a self-
D Follow requirements in NFPA 70E for safe work practices and retaining spring clip such as an alligator clip.
Personal Protective Equipment (PPE). D Read instructions for test equipment.
OM-271146 Page 51
FALLING EQUIPMENT can injure. H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running D High-frequency (H.F.) can interfere with radio
gear, gas cylinders, or any other accessories. navigation, safety services, computers, and
D Use equipment of adequate capacity to lift and communications equipment.
support unit. D Have only qualified persons familiar with
electronic equipment install, test, and service
D If using lift forks to move unit, be sure forks are long enough to H.F. producing units.
extend beyond opposite side of unit.
D The user is responsible for having a qualified electrician prompt-
D Follow the guidelines in the Applications Manual for the Revised ly correct any interference problem resulting from the installa-
NIOSH Lifting Equation (Publication No. 94−110) when manu- tion.
ally lifting heavy parts or equipment.
D If notified by the FCC about interference, stop using the
MOVING PARTS can injure. equipment at once.
D Have the installation regularly checked and maintained.
D Keep away from moving parts such as fans. D Keep high-frequency source doors and panels tightly shut, keep
D Have only qualified persons remove doors, spark gaps at correct setting, and use grounding and shielding to
panels, covers, or guards for maintenance and minimize the possibility of interference.
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF) READ INSTRUCTIONS.
can affect Implanted Medical Devices.
D Use Testing Booklet (Part No. 150 853) when
D Wearers of Pacemakers and other Implanted servicing this unit.
Medical Devices should keep away from serv- D Consult the Owner’s Manual for welding safety
icing areas until consulting their doctor and the precautions.
device manufacturer. D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully be-
OVERUSE can cause OVERHEATING. fore installing, operating, or servicing unit. Read the safety in-
formation at the beginning of the manual and in each section.
D Allow cooling period; follow rated duty cycle. D Perform installation, maintenance, and service according to the
D Reduce current or reduce duty cycle before us- Technical Manual, industry standards, and national, state, and
ing induction heating equipment again. local codes.
D Do not block or filter airflow to unit.
9-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
9-4. EMF Information

Electric current flowing through any conductor causes localized electric 3. Do not coil or drape cables around your body.
and magnetic fields (EMF).The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and 4. Keep head and trunk as far away from the equipment in the
induction heating operations) creates an EMF field around the welding welding circuit as possible.
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants 5. Connect work clamp to workpiece as close to the weld as
have to be taken. For example, restrict access for passers−by or con- possible.
duct individual risk assessment for welders. All welders should use the
6. Do not work next to, sit or lean on the welding power source.
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a
cable cover. Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
2. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom-
to one side and away from the operator. mended.
OM-271146 Page 52
SECTION 10 − DIAGNOSTICS & TROUBLESHOOTING
The ProHeat 35 power source has on-board capabilities to aid in troubleshooting problems should any conditions occur during operation. This
troubleshooting capability consists of the Fault LED, Limit LED, and message screens that appear on the front panel LCD display.
10-1.Operator Interface Indicators
1 2 3
803 995-B
1 Fault LED 2 Limit LED 3 4 x 40 LCD Display

Displays programming, run status, param-
LED lights to indicate a system fault LED lights to indicate a system limit eters, fault and limit conditions, and
condition. condition. troubleshooting guide.
OM-271146 Page 53
10-2.Limit Conditions
A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its optimum operating conditions or
parameters. Should a limit condition occur during operation, the yellow Limit LED will flash to indicate a problem. If the active screen on the LCD display
is Run Status or Parameters, a message describing the particular limit condition will appear on the display. If the active screen is Program, press the
Run Status button to display the limit condition.
In a limit condition, the power source will continue to deliver output power and protect itself from damage by reducing the output power. This situation
allows the operator time to determine the best action to correct the problem as described by the limit message on the LCD display.
If a limit condition occurs, there are two selectable options:
S Acknowledge the limit and continue operation.
S Terminate operation to correct the problem causing the limit.
Pressing the Decrease button will acknowledge the limit and continue operation with the existing set up. In the acknowledge state, the yellow
Limit LED will stop flashing and remain on continuously. The LCD display will revert to an active screen once the Program button, Run Status
kW
button, or Parameters V
A button is pressed.
Hz
If a new limit condition should occur after the first is acknowledged, the yellow Limit LED will start flashing to indicate a new problem. To display the limit
condition, press the Run Status button and the LCD display will show a message describing the new and previous limit messages.
To obtain additional information regarding the limit condition and suggested solutions to resolve the limit, press the Increase button, and the
LCD display will indicate possible solutions based on the type of limit condition.
If the operator determines that the best course of action is to terminate operation and make suggested changes to the setup to eliminate the limit condi-
tion, press the Stop button. After changes are made to the setup, press the Run button to restart the process.
10-3.Limit Condition Codes

Limit Condition Additional Information
L01: Thermocouple #1 Open Check for open temperature sensor and repair
Change to back-up temperature sensor
L07: Output Voltage Limit Tighten blanket against pipe surface
Shorten extension cable
L08: Output Voltage Limit Increase number of turns
Increase coil space
Shorten extension cable
Increase insulation width
L09: Output Current Limit Tighten blanket against pipe surface
L10: Output Current Limit Increase number of turns
Decrease coil space
Tighten cable on insulation
OM-271146 Page 54
Limit Condition Additional Information
L11: Coolant Overtemp Limit Check coolant flow and level
Clean coolant filters and heat exchanger
Increase number of turns
Verify appropriate insulation thickness
L12: Power Source Overtemp Limit Check for blocked vents
Clean wind tunnel heat sinks
L13: Cable Connection Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
Check cable 1 and cable 2 identification on diagnostic screen DIAG1 (see Section 10-7)
L14: Accessory Temperature Limit Check Accessory TC connection
Wait for accessory to cool
L15: Low Travel Speed Increase travel speed.
Check travel detector.
10-4.Fault Conditions
A fault condition occurs if the system encounters an isolation fault, encounters operating conditions outside operational limits, or if there is a serious
problem with the system. Should a fault condition occur, the output is immediately turned off, the red Fault LED flashes and the Stop button
LED flashes. If the active screen on the LCD display is Run Status or Parameters, a message describing the particular fault condition will appear on the
display. If the active screen is Program, press the Run Status button to display the fault condition.
Pressing the Decrease button will acknowledge the fault and the red Fault LED will stop flashing and remain on continuously. However, the
Stop button LED will continue to flash indicating that the process has stopped.
To obtain additional information regarding the fault condition and suggested solutions to resolve the fault, press the Increase button, and the
LCD display will indicate possible solutions based on the type of fault condition. In most cases, a fault condition will indicate that service is required.
10-5.Fault Condition Codes

Fault Condition Additional Information
F51: Thermocouple #1 Internal Fault Service required
F57: CJT Sensor Internal Fault Service required
F58: Output Voltage Fault Air cooled systems:
Tighten blanket against pipe surface
Reduce length of extension cable
Liquid cooled systems:
Increase coil space
Reduce length of extension cable
Increase insulation width
Service required
F59: Output Current Fault Service required
F60: Temperature Sensor Fault Check control TC connections
Check control TC extension cable
Check control TC type in SYSTEM SETUP2
F61: Coolant Flow Fault Check for coolant leak
Clean for coolant blockage
Check coolant filter and level
Check coolant connections
OM-271146 Page 55
Fault Condition Additional Information
F62: Isolation Fault Check for exposed conductor or for moisture on blanket
Using conductive coolant in cooler (043810 low conductivity coolant is recommend).
F63: Line Voltage Fault Check line voltage
Check voltage values on diagnostic screen DIAG2 (see Section 10-7)
F64: Power Source Overtemp Fault Verify power source vents and
wind tunnel are unobstructed
F65: Current Source Fault Service required
F66: Under Frequency Fault Check for loose or open connections in output cable
Decrease number of turns or add a second output
Decrease coil space
Service required
F67: Over Frequency Fault Verify heating cable properly wrapped
Verify material being heated is magnetic
F68: Cable Connection Fault Check for loose/open output connection
Verify all output cables are same type
Verify receptacle plug connected
Check cable 1 and cable 2 identification on diagnostic screen DIAG1 (see Section 10-7)
Rolling Inductor only: Verify TC5, TC6 connection.
F69: Coolant Overtemp Fault Check coolant flow and level
Clean coolant filters and heat exchanger
Verify appropriate insulation thickness
F70: Internal Communication Fault Service required
F71: Internal Thermistor Fault Service required
F72: Coolant Thermistor Fault Service required
F73: Decoupled/Open Coil Check for loose/open output connection.
Tighten coil/blanket.
F74: Isolation Fault Self-Test Error Service required
F75: Internal Power Supply Fault Service required
F76: Current Source Control Fault Service required
F77: Power Source Internal Comm Fault Service required
F78: Output Current Sense Fault Check for loose/open output connection or an extension cable connected with no coil attached
at the end.
Service required
F79: Accessory 1 overtemp fault Check accessory TC connection
F80: Accessory 2 overtemp fault Check accessory TC connection
OM-271146 Page 56
10-6.Infrared Sensor Troubleshooting Guide
Problem Cause Potential Solution
Err Infrared sensor is connected but Verify settings on ProHeat are set for IR 4−20 mA, and temp range is
temperature is not in range. set to 212°F−752°F (100°C−400°C) if infrared sensor is attached.
Verify settings on ProHeat are set for K TC if thermocouple measuring

device is attached.
Low Infrared sensor is connected but The ”Low” setting is +/− 41°F (5°C) of the low limit of the infrared sensor
temperature output is below sensor temperature range of 212°F (100°C).
range.
If necessary, use alternative method to verify temperature of material be-
ing heated.
High Infrared sensor is connected but The ”High” setting is +/− 41°F (5°C) of the high limit of the infrared sensor
temperature output is above sensor temperature range of 752°F (400°C).
range.
If necessary, use alternative method to verify temperature of material be-
ing heated.
Open No thermal couple measuring device If infrared sensor is connected, verify settings on ProHeat are set for an
detected. infrared sensor. Verify continuity of cable connections replace if neces-
sary.
Verify infrared sensor is working correctly, replace if necessary.
If thermocouple measuring device is connected, verify continuity of exten-

sion cable and measuring device, replace if necessary.
10-7.System Diagnostic Screens

Additional system diagnostics are available and accessible through the operator interface. Detail operational parameters can be accessed by pressing
kW
and holding the Run Status button and pressing the Parameters V
A button.
Hz
When this feature is initially activated, the following screen appears on the LCD display:
System Diagnostic Screen
RemCmd: 1023 Off Cable1: LQD DIAG1

OutI1: 0 A Cable2: LQD
OutI2: 0 A ClntFR: 0.60 GPM
IsrcFb: 0 A ClrSts: Flowing
RemCmd − This is the value of the remote command and the status of the remote contactor.
. Remote controls can be used to enable/disable output in all control modes. They only affect output power level when the control mode is set to
Remote.
Out I1 − This is the value of the output current on output 1.

Out I2 − This is the value of the output current on output 2.
Isrc FB − This is the value of the amperage in the current source inverter.
Cable 1 − This is the cable type hooked up to output number one. Possible labels:
S AIR − for an air-cooled cable
S LQD − for a liquid-cooled cable
S PLUG − for a protective plug
S OPEN − no cable or plug in place
S ROLL − rolling Inductor
OM-271146 Page 57
Cable 2 − This is the cable type hooked up to output number two. Possible labels:
S AIR − for an air-cooled cable
S LQD − for a liquid-cooled cable
S PLUG − for a protective plug
S OPEN − no cable or plug in place
S ROLL − rolling inductor
ClntFR − This is the coolant flow rate (in GPM) from the cooler on a liquid-cooled system.
ClrSts − This is the status of the cooler. Possible labels:
S Off
S Flowing
kW
The second diagnostic screen is available by again pressing and holding the Run Status button and pressing the Parameters V
A button.
Hz
System Diagnostic Screen
VLnA−B: 460V Therm1: 75 DIAG2

VLnB−C: 460V Therm2: 75 Therm5: OPEN
VLnC−A: 460V Therm3: 75 ClrTmp: 77
VBus: 650V Therm4: OPEN RmtFlw: Off
VLnA-B − This is the phase to phase line voltage between phases A and B.
VLnB-C − This is the phase to phase line voltage between phases B and C.
VLnC-A − This is the phase to phase line voltage between phases C and A.
VBus − This is the DC bus voltage.
Therm1 − This is the temperature of the current source primary heatsink.
Therm2 − This is the temperature of the bridge heatsink.
Therm3 − This the the temperature of the current source secondary heatsink.
Therm4 − Open (not used).
Therm5 − Open (not used).
ClrTmp − This is the temperature of the coolant on a liquid-cooled system.
S OPEN − no cooler is detected.
RmtFlw − This is the status of the relay contacts for remote coolant flow on a liquid-cooled system.
S OFF
S ON
. RmtFlw feature is unsupported on the current platform.
OM-271146 Page 58
10-8.ProHeat 35 Firmware Versions And Compatibility
Release Date Eff Stock And PC Board No. PC Board Revision No. PC Board Reason
Serial No. Name Stock No.
Original Release 907689, PC2 Operator Interface 1.29-
MG220055G- Currently 1.30 274028
907690 PC1 Bridge Control uP 1.25-

MF310067G- Currently 1.27 273113
The Bridge Control PLD is 1.28, and has not changed since the ProHeat 35 was released.
If possible, verify firmware revision levels prior to ordering circuit boards.
If firmware revisions cannot be verified, contact Miller Service for instructions on updating firmware.
All boards are compatible with firmware updates so the part number on old boards does not indicate firmware revision.
kW
Press and hold the the Run Status and the Parameters V
A buttons for a minimum of four seconds to verify current firmware revisions.
Hz
System Firmware Revisions Screen
Firmware Revisions
Operator Interface 0.01
Bridge Control uP 0.01
Bridge Control PLD 1.00
OM-271146 Page 59
10-9.Removing Wrapper and Measuring Input Capacitor Voltage
! Turn Off welding power
source, and disconnect
input power.
! Significant DC voltage can
Tools Needed:
remain on capacitors after
unit is Off. Always check the
5/16, 3/8 in. voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
Remove right side panel and dis-
connect fan motor FM3.
1 Current Source Interconnect
Board PC4
2 Voltmeter
Measure the dc voltage across the
+ bus terminal and − bus terminal on
PC4 as shown until voltage drops to
near 0 (zero) volts.
. If the capacitor voltage does

not drop to near zero after
several minutes, use a bleeder
resistor of between 200 and
500 ohms, at least 10 watts,
and #16 AWG 600 volts ac in-
sulation rated wire to discharge
the capacitor(s).
3 Typical Bleeder Resistor
An example of a typical bleeder
1 resistor is shown on this page.
Proceed with job inside unit. Re-
connect FM3 and reinstall right side
panel when finished.
+ lead to right bus terminal, 3

− lead to left bus terminal
Typical Bleeder Resistor

200 to 500 ohm, 10 watt
wire wound resistor
#16 AWG 600 Volts AC

Insulation Rating
804 519-C
OM-271146 Page 60
10-10.Blowing Out Inside Of Unit
! Turn Off welding power
source and disconnect input
power.
! Remove wrapper and be
sure input capacitors are
discharged.
Blow out inside of unit. Blow out fan
motors in right side panel and front
panel.
804 625-B
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)

22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
OM-271146 Page 61
SECTION 11 − ELECTRICAL DIAGRAM
Figure 11-1. Circuit Diagram
OM-271146 Page 62
271 167-A
OM-271146 Page 63
SECTION 12 − PARTS LIST
5 3 . Hardware is common and

not available unless listed.
4
12
13
See Figure
12-3
14 11
15
9 8
11
6
See Figure
12-2
10
2 Ref. 804 218-D
Figure 12-1. Wrappers
Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 12-1. Wrappers
. . 1 . . . . . . . . . . . . . +217470 .. Panel, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 274968 .. Label, Warning Electric Shock And Incorr (En/Fr/Sp) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194466 .. Label, Warning Electric Shock And Input Pwr (Ce) . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . +217325 .. Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 147876 .. Label, Warning General Precautionary Induction Heat . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 217334 .. Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 217468 .. Door, Primary Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 218280 .. Hinge, Cont Polyolefin Copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 222106 .. Bracket, Mtg Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . FM3 . . . . 236263 .. Fan, Muffin 24vdc 3000 Rpm 130 CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 206270 .. Insulator, Side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 11 . . . . . . . . . . . . . . 197900 .. Cable, Work Ground (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 271878 .. Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 271466 .. Grip, Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 271842 .. Magnet, Permanent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 263801 .. Plug, Tw Lk Insul Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC2 . . . . 135635 .. Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . 131054 .. Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG61 . . . 131204 .. Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG63 . . . 115094 .. Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+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 Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-271146 Page 64
. Hardware is common and 14 5
not available unless listed. 1
4
15
8
11 12
13
6
7
10
9
Ref. 804 219-D
Figure 12-2. Front Panel

Item Dia. Part
Figure 12-2. Front Panel
. . 1 . . . . . . . . . . . . . . 217323 . . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 216225 . . . . Nameplate, Proheat 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 216224 . . . . Panel, Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . TC1−TC6 . . 218686 . . . . Receptacle Assy, Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 5 . . . . . . . . . . . . . . 217327 . . . . Plate, TC Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . S1 . . . . . 244920 . . . . Switch, Tgl 3pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 252731 . . . . Label, Warning Read Labels On/Off Storage Temp . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 221493 . . . . Label, TC 1−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 115440 . . . . Standoff, No 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . 10 . . . . . . . . . . . . . . 224143 . . . . Gasket, Meter Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . PC10 . . . . 239271 . . . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . PC2 . . . . 274028 . . . . Circuit Card Assy, Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG24 . . . 115091 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 247615 . . . . Gasket, Operator Interface Proheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 246430 . . . . Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 203310 . . . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 65
. Hardware is common and 11
12 5
8
13
1
7
2
4
6
804 220-B
10
Figure 12-3. Rear Panel
Item Dia. Part
Figure 12-3. Rear Panel
. . . 1 . . . . . . . . . . . . . . 217324 .. Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . RC1 . . . . . . 252561 .. Receptacle, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 127837 .. Receptacle, Tw Lk Insul Fem (Dinse Type) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . CB1 . . . . . . 089807 .. Supplementary Protector, Man Reset 1p 2.5 A 250 VAC . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 220824 .. Cover, Receptacle Weatherproof Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . +218689 .. Panel, Rear Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 602498 .. Label, Danger High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . RC14 . . . . . 143976 .. Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . RC9 . . . . . . 047637 .. Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 224989 .. Receptacle Assy, Output (With Leads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 234531 .. Shell, W/Contact Pin And Socket (Service Kit For 224 989) . . . . . . . . . . . 0
. . . 11 . . . . . . . . . . . . . . 224042 .. Connector, Circ Cpc Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 170391 .. Connector, Circ Ms Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 147195 .. Nut, 375−27 .54 Hex .25 H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . RC21,22 . . . . 135635 .. Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG21,22 . . . 131054 .. Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-271146 Page 66
. Hardware is common and
14 12
6
2
5
17
10
13
7 18
3
6
9 16
15
8
272 741-A
Figure 12-4. Base w/Components
Item Dia. Part

Figure 12-4. Base w/Components
. . . 1 . . . . . . . . . . . . . . 217328 . . Frame, Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 213865 . . Base Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 213939 . . Label, Warning Electric Shock Can Kill Significant . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 227085 . . Label, Warning Electric Shock Can Kill Wordless 150 . . . . . . . . . . . . . . . . . 2
. . . 4 . . L1,L2 . . . . . 218692 . . Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . 216815 . . Bracket, Cap Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . C1,2 . . . . . 213870 . . Capacitor, Elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . T1 . . . . . . 213583 . . Transformer, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . T1 . . . . . . 227065 . . Transformer, Hf (400V Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 216629 . . Bracket, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . FM1,FM2 . . . 224694 . . Fan, Muffin 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . RC4 . . . . . . 115090 . . Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 217992 . . Baffle, Air Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 224973 . . Insulator, Lift Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 603115 . . Weatherstripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 026627 . . Gasket, Lifting Eye Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4 . . . . . 115094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 226837 . . Washer, Rubber .343 ID X .875 OD X .093 Thk . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 226838 . . Insulator, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 271847 . . Block,Term 115 Amp 1 Pole Screw Term 2−14 Wire . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 272440 . . Lead Assy, PE With Ferrite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 67
18 20
19
17 9
7
11
17
10
3
13 1
7
12
8 22
16
5
6
14
15
4 2
272 733-B
Figure 12-5. Top Windtunnel

Item Dia. Part
Figure 12-5. Top Windtunnel
... 1 .............. 218424 .. Windtunnel, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 218684 .. Heat Sink, AC Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 025248 .. Standoff, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . RT2 . . . . . . 222327 .. Thermistor, Ntc 30 K Ohm At 25 Deg C 24 In. Lead . . . . . . . . . . . . . . . . . . 1
... 5 .............. 083147 .. Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . . 2
... 6 .............. 605339 .. Washer, Tooth .377 ID X 0.507 OD X .022t Stl Pld . . . . . . . . . . . . . . . . . . . 2
... 7 .............. 098691 .. Stand−Off, No 6−32 X .500 Lg .250 Hex Stl M&F . . . . . . . . . . . . . . . . . . . 6
... 8 .............. 217326 .. Bracket, TC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 250975 .. Insulator, Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 229382 .. Support, Leads Bridge Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . PC5 . . . . . . 271177 .. Kit, Circuit Card Assy Intrcnct Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . PC3 . . . . . . 272649 .. Circuit Card Assy, Tc Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 208591 .. Screw, M 5− .8 x 12 Soc Hd−Torx Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . 12
. . . 13 . . . . . . . . . . . . . . 212038 .. Screw, M4 − .7 X 8.5 Pan Hd−Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 14 . . . . F1 . . . . . . 225514 .. Fuse, Crtg 2. Amp 600 V Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 225553 .. Holder, Fuse Crtg 30 A 600 V 13/32 X 1−1/2 Lg . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 229382 .. Support, Leads Bridge Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 227863 .. Stand−Off, No 6−32 X .750 Lg .250 Hex Stl M&F . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 247231 .. Cover, TC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 251158 .. Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 68
Item Dia. Part
Figure 12-5. Top Windtunnel (continued)
. . . 20 . . . CT3 . . . . . . 220822 . . Xfmr, Current Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . CT4, CT5 . . . 220823 . . Xfmr, Current Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG32 . . . . 115091 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG33-38,54 . . 131204 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . PLG51,57 . . . 115091 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . L3 . . . . . . 227082 . . Choke, Common Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 69
20 1
2
19
3 6
10
18 17
15
16
11
13
14 12
272 717-A
Figure 12-6. Right Windtunnel
Item Dia. Part

Figure 12-6. Right Windtunnel
... 1 .............. 216230 .. Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 115443 .. Stand-Off, No 6−32 X .750 Lg .250 Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 3 . . . RT1 . . . . . . 222326 .. Thermistor, NTC 30 K Ohm At 25 Deg C 34 In. Lead . . . . . . . . . . . . . . . . . 1
... 4 .............. 170647 .. Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 030170 .. Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 223120 .. Block, Term 115 Amp 3 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .............. 145743 .. Lug, Univ W/Scr 600V 2−14 Wire .250 Stud . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . PC6 . . . . . . 269981 .. Circuit Card Assy, Cooler Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 229337 .. Screw, M 5− .8x 12 Soc Hd−Torx Stl Pld Sems (Used W/Q1 − Q6, D1) . 14
... 10 .............. 229728 .. Strap, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 .............. 176879 .. Screw, M5 − .8 X 12 Hex Hd−Phl 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
... 12 .............. 212038 .. Screw, M4 − .7 X 8.5 Pan Hd−Phl Stl Pld (Used W/ SR1) . . . . . . . . . . . . . 2
... 13 . . . PC8 . . . . . . 239275 .. Circuit Card Assy, Bus Intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . PC4 . . . . . . 271181 .. Kit, Circuit Card Assy Intrcnct I Srce Inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 213871 .. Grommet, Rbr Sil 3.000 Id X 3.250 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . 2
... 16 .............. 224391 .. Panel, Insulating Mtg Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 .............. 605339 .. Washer, Tooth .377 ID X 0.507 OD X .022t Stl Pld . . . . . . . . . . . . . . . . . . . 2
... 19 .............. 213873 .. Heat Sink, Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 70
Item Dia. Part
Figure 12-6. Right Windtunnel (Continued)
. . . 20 . . . . . . . . . . . . . . 245842 . . Assy, Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . PLG64,410,
411 . . . . . . 115093 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . PLG65 . . . . 271089 . . Housing Rcpt+Skts,(Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG111, 112
121, 132,
141, 142 . . . . 131054 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OM-271146 Page 71
1
21
6
20
2 5
8
10
11
18
19
16
17
12
15 14
272731-A
13
Figure 12-7. Right Windtunnel (400 V Model Only)
Item Dia. Part

Figure 12-7. Right Windtunnel (400 V Model Only)
... 1 .............. 253366 .. Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . RT1 . . . . . . 222326 .. Thermistor, NTC 30 K Ohm At 25 Deg C 34 In Lead . . . . . . . . . . . . . . . . . 1
... 3 .............. 170647 .. Bushing, Snap-In Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 030170 .. Bushing, Snap−In Nyl .750 ID X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 226041 .. Bracket, Mtg CE Filter Ground Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . PC6 . . . . . . 269981 .. Circuit Card Assy, Cooler Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . PC9 . . . . . . 272648 .. Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 229337 .. Screw, M 5− .8x 12 Soc Hd−Torx Stl Pld Sems (Used W/Q1− Q6, D1) . . 14
... 10 .............. 226579 .. Spacer, Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 .............. 229728 .. Strap, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 12 .............. 176879 .. Screw, M5 − .8 X 12 Hex Hd−Phl 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
... 13 .............. 212038 .. Screw, M4 − .7 X 8.5 Pan Hd−Phl Stl Pld (Used W/SR1) . . . . . . . . . . . . . . 2
... 14 . . . PC8 . . . . . . 239275 .. Circuit Card Assy, Bus Intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . PC4 . . . . . . 271181 .. Kit, Circuit Card Assy Intrcnct I Srce Inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 213871 .. Grommet, Rbr Sil 3.000 ID X 3.250 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 .............. 224391 .. Panel, Insulating Mtg Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 72
Item Dia. Part
Figure 12-7. Right Windtunnel (400 V Model Only) (Continued)
. . . 19 . . . . . . . . . . . . . . 605339 . . Washer, Tooth .377 ID X 0.507 OD X .022t Stl Pld . . . . . . . . . . . . . . . . . . . 2

. . . 20 . . . . . . . . . . . . . . 213873 . . Heat Sink, Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 245842 . . Assy, Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG64,410,
. . . . . . . . PLG65 . . . . 271089 . . Housing Rcpt+Skts,(Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG111, 112
121, 132,
141, 142 . . . . 131054 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OM-271146 Page 73
2
8
6
13
14
10
3 15
5
11
9
Figure 12-8. Left Windtunnel 272 732-A
Item Dia. Part

Figure 12-8. Left Windtunnel
... 1 .............. 216631 .. Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 218683 .. Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 170647 .. Bushing, Snap-In Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 025248 .. Stand-Off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . RT3 . . . . . . 222327 .. Thermistor, Ntc 30 K Ohm At 25 Deg C 24 In. Lead . . . . . . . . . . . . . . . . . . 1
... 8 .............. 030170 .. Bushing, Snap-In Nyl .750 ID X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 218430 .. Cover, Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 220825 .. Bus Bar, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . C7-C10 . . . . 218687 .. Capacitor, Polyp Film 1.35 UF 700 VAC +5% −0% . . . . . . . . . . . . . . . . . . . 4
. . . 11 . C7-C10 . . . . 225775 .. Capacitor, Polyp Film 1.10 UF 700 VAC +5% −0% (400 V Model Only) 4
. . . 12 . . . . T2 . . . . . . 219002 .. Transformer, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PC7 . . . . . . 239266 .. Kit, Circuit Card Assy Intrcnct I Srce Out . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PC1 . . . . . . 272714 .. Circuit Card Assy, Power Source Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 212038 .. Screw, M4 − .7 X 8.5 Pan Hd−Phl Stl Pld Slffmg . . . . . . . . . . . . . . . . . . . . . 8
.................... 272438 .. Capacitor/Resistor (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 74
Item Dia. Part
Figure 12-8. Left Windtunnel (Continued)
. . . . . . . PLG16,
121,122 . . . . 131054 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . PLG19,
. . . . . . . PLG15,
. . . . . . . PLG77,
. . . . . . . PLG18,
116 . . . . . . 131056 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG13,
. . . . PLG15, RC115 . 271504 . . Housing Plug+Skts,(Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-271146 Page 75
3 5
1
3
9 804 300-A
Figure 12-9. Hermaphroditic Blank Plug Assy

Item Dia. Part
Figure 12-9. Hermaphroditic Blank Plug Assy 224 260
... 1 .............. 221440 .. O-Ring, .737 Id X .103 Cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 2 .............. 252628 .. Socket, 14mm Blank Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 221099 .. Clamp, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 136343 .. Screw, K50 X 20 Pan Hd-Phl Stl Pld Pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 .............. 224261 .. Cap, Plug Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 254886 .. Collar, Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .............. 254885 .. Retainer, Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 252627 .. Pin, 14mm Blank Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 253842 .. Shell Assy, Connector - Protective Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 76
4
1
3 2
7
6 5
804 324-A
Figure 12-10. Air−Cooled Output Extension Cables
Item Dia. Part

Figure 12-10. Air−Cooled Output Extension Cables 195 404, 195 405, And 300 362
... 1 .............. 253841 .. Shell Assy, Connector − Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 254886 .. Collar, Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 221099 .. Clamp, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 136343 .. Screw, K50 x 20 Pan Hd−Phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . 2
... 5 .............. 254887 .. Shell, Connector Cable Female With Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 .............. 224259 .. Clamp, Strain Relief Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 7 .............. 228296 .. Screw, Ka35x10 Pan Hd−Phl Sst Pln Pt Thread Forming . . . . . . . . . . . . . 4
... 8 .............. 197635 .. Label, Warning Flexible Induction Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-271146 Page 77
2 1
4 3
6
6 5
7
11
8
4 9
10
804 411-A
Figure 12-11. Liquid−Cooled Output Extension Cables
Item Dia. Part

Figure 12-11. Liquid−Cooled Output Extension Cables (195 402, 195 403, 300 180, And 300 598)
... 1 .............. 253840 .. Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 254886 .. Coupling Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 221099 .. Strain Relief Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 136343 .. Screw K50 X 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 .............. 210912 .. Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 6 .............. 204954 .. Quick Connect Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 7 .............. 254889 .. Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 .............. 254890 .. Coupling Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 .............. 224258 .. Strain Relief Pin Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 10 .............. 228296 .. Screw Ka35x10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 .............. 197635 .. Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 78
2
3
804 404-A
Figure 12-12. Heating Cables
Item Dia. Part

Figure 12-12. Heating Cables (300 045, 300 046, 300 047, And 300 049)
.. 1 .............. 254887 .. Connector Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

.. 2 .............. 204954 .. Plastic Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 3 .............. 210912 .. Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 4 .............. 224259 .. Strain Relief Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 5 .............. 228296 .. Screw, KA35x10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 6 .............. 197635 .. Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-271146 Page 79
1
201 432-G
Figure 12-13. Quick Connect To Quick Connect Hose
Item Dia. Part

Figure 12-13. Quick Connect To Quick Connect Hose (204 877)
. . 1 . . . . . . . . . . . . . . 204955 . . Ftg, Plstc Coupler Qdisc X 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 227601 . . Hose Assy, Coolant Series Adapt 24in Quick To Quick
. . . . . . . . . . . . . . . . . . . . 201430 . . Hose Assy, Coolant 36 In Lh Thread To Quick Connect
OM-271146 Page 80
1
4 13
6 7 8 9
3 10
11
Replaceable
Strap
12
Strap
Buckle
Ref. 805 176-C / Ref. 805 174-C
Figure 12-14. Induction Blanket And Sleeve

Item Part
No. No. Description Quantity
Figure 12-14. Induction Blanket And Sleeve
... 1 .... 196666 .. Screw, 008−32 X 1.50 Rnd Hd−Slt Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 2 .... 196665 .. Cleat, Rope 4 In. Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .... 196669 .. Screw, 010−12 X .63 Pan Hd−Phl Sst Pln Sht Met Ab . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 4 .... 020265 .. Cable Tie, 0−1 .750 Bundle Dia Sst2s−Mp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 .... 228296 .. Screw, Ka35 X 10 Pan Hd−Phl Sst Pln Pt Thread Forming . . . . . . . . . . . . . . . . . . . . . . 4
... 6 .... 254889 .. Shell, Connector Cable Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .... 254890 .. Collar, Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 .... 224145 .. Pin, Radsok 14mm Cable End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 .... 224258 .. Clamp, Strain Relief Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 10 . . . . 196965 .. Wearplate, Induction Blanket 6.125 in. wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . 259960 .. Wearplate, Induction Blanket 5.000 in. wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . 197866 .. Strap, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Part
No. No. Description Quantity
Figure 12-14. Induction Blanket And Sleeve (continued)
OM-271146 Page 81
. . . 12 . . . . 195337 . . Induction Blanket Sleeve, 13-7/64 In. (229 mm) Wide, 41 In. (1041 mm) Long [8-5/8 In.
. . . . . . . . . . . . . . . . . . . . (219 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . 195338 . . Induction Blanket Sleeve, 11-5/16 In. (287 mm) Wide, 45 In. (1143 mm) Long [10-3/4 In.
. . . . . . . . . . . . . . . . . . . . (273 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . 194889 . . Induction Blanket Sleeve, 10-7/64 In. (257 mm) Wide, 49 In. (1245 mm) Long [12 In.
. . . . . . . . . . . . . . . . . . . . (305 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (356 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (406 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . 194707 . . Induction Blanket Sleeve, 9 In. (229 mm) Wide, 68 In. (1727 mm) Long [18 In.
. . . . . . . . . . . . . . . . . . . . (457 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . 198664 . . Induction Blanket Sleeve, 9 In. (229 mm) Wide, 74 In. (1880 mm) Long 20 In.
. . . . . . . . . . . . . . . . . . . . (508 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (559 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (610 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (660 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (711 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (762 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (813 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (864 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (914 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (965 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1016 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1067 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1118 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1168 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1219 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1321 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1422 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1219 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1422 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1524 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1829 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . (1321 mm) Dia Pipe] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . 274885 . . Label,Warning Read Owner’S Manual Wordless Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Replacement Parts.
OM-271146 Page 82
6
21
11
5 13
10 12
4 3
2 27
23
1 24 22 14
25
15
5
16
26
2
25
1 4 3
22 24
6
19 17
18
20
Ref. 263 983-C
Figure 12-15. Rolling Inductor Complete Assembly

Item Dia. Part
Figure 12-15. Rolling Inductor Complete Assembly
... 1 . . . . . . . . . . 262163 . . Plate, Side W/Pems Rolling Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 2 . . . . . . . . . . 263693 . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . . . . . . . . . 263696 . . Washer, Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 4 . . . . . . . . . . 263530 . . Wheel, Rolling Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 5 . . . . . . . . . . 265978 . . Bracket,Travel Sensor Mtg Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . . . . . . . 263213 . . Bracket, Mtg Temperature Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 . . . . . . . . . . 262268 . . Plate,Top W/Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . 262166 . . Handle, Plastic Rolling Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . 263854 . . Bracket, Rolling Inductor Strain Relief Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . 263690 . . Spacer, Glass Polyester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 204954 . . . . Ftg, Plstc Nipple Qdisc X 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . 210912 . . . . Cap, Protective Rbr Quick Connect Nipple Black . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . . . . . . . . . 264119 . . . . Shell Assy, Connector - Rolling Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . 254886 . . . . Collar, Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . 136343 . . . . Screw, K5 0x 20 Pan Hd-phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . . . . 2
OM-271146 Page 83
Item Dia. Part
Figure 12-15. Rolling Inductor Complete Assembly (Continued)
. . . 16 . . . . . . . . . . 221099 . . . . Clamp, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 17 . . . . . . . . . . 263904 . . . . Label,Warning Flexible Induction Cords 9672 PSA . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 194962 . . . . Connector, TC Type K 3-pin Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 262174 . . Insulation, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 262194 . . Wearplate, Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 262172 . . Handle Assy, Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 259455 . . Spacer, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . 263732 . . Hinge, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 263697 . . Extrusion, W/Rivnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . 262173 . . Insert, Extrusion Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . 262183 . . Insulation, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 263986 . . Spacer, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 263854 . . Bracket, Mtg IR Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. Hardware is common and not

available unless listed.
1
8
4
5
2
9
3
1 2
264 092-B
Figure 12-16. Rolling Inductor Mounting Arm Assembly

OM-271146 Page 84
Item Dia. Part
Figure 12-16. Rolling Inductor Mounting Arm Assembly
. . 1 . . . . . . . . . . . . . . 263529 . . Plate, Swivel Induction Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 2 . . . . . . . . . . . . . . 263665 . . Bushing, Swivel Induction Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 3 . . . . . . . . . . . . . . 263533 . . Assy, Swivel Shaft Induction Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 264044 . . Screw, Thumb Sst 10-32 X 1.00 Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . . . 263528 . . Housing, Swivel Induction Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 261778 . . Hinge, Spring Induction Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 263534 . . Assy, Induction Arm Attachment Welded . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 124778 . . Knob, T 2.000 Bar W/.312-18 Stud 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 259968 . . Bolt, Eye Shld Thd Stem .375-16 X 1.500 Fbrgls . . . . . . . . . . . . . . . . . . . . 1

10 11
9 12
1
16
2
13
14
4
5
6
7
3
15
270 112-B
Figure 12-17. Rolling Inductor Stand

Item Dia. Part
Figure 12-17. Rolling Inductor Stand
.. 1 .............. 269173 .. Pin, Quick Release .375 Dia X 1.300 Usable LG . . . . . . . . . . . . . . . . . . . . . 1

.. 2 .............. 269165 .. Tube Assy, Small Welded Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . 1
.. 3 .............. 269174 .. Bolt, T-handle 375-16 X 3.688 L Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 4 .............. 269169 .. Plate, Locking Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 85
. . 5 . . . . . . . . . . . . . . 271153 . . Spacer, Cable Mount .375 THK GFPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 271152 . . Support, Cable J−Hook Nylon 2.000in Bundle Blk . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . +269153 . . Assy, Welded Base Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 269519 . . Label, Warning Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 269159 . . Tube Assy, Middle Welded Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 269678 . . Clip, C .500ID X .938OD X .150THK Nylon w/tab . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . . . 269406 . . Assy, Head Rolling Inductor Stand (Includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 192362 . . . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . . . 269448 . . . . Stand−Off, No 10−32 X .250 Lg .375 Hex SST . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . . . . . . . . . . . . . . 269171 . . . . Foot, Push Rivet .59ODX.35H .04-.08THK .165 Mtg Blk . . . . . . . . . . . . 4
. . 14 . . . . . . . . . . . . . . 269170 . . . . Spring, Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 15 . . . . . . . . . . . . . . 269161 . . . . Bracket Assy, Welded Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 269166 . . . . Bracket Assy, Top Rolling Inductor Stand . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-271146 Page 86
6
5
7
4
9
10
2
11
266 226-B
Figure 12-18. Travel Sensor Assembly w/Mounting Bracket
Item Dia. Part
Figure 12-18. Travel Sensor Assembly w/Mounting Bracket
. . 1 . . . . . . . . . . . . . . 266229 . . O-Ring, 3.350 ID X 3.770 OD Silicone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 266228 . . Wheel, Travel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 266074 . . Bracket, Travel Sensor Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 267352 . . Knob Assy, Bracket Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 266224 . . Pin, Clevis .250 OD X 2.750 LG W/.094 Hole Stls . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 262553 . . Knob, Threaded Three Arm Phenolic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 266751 . . Spacer, AL .250 ID X .500 OD X 1.00 LG . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 266223 . . Clamp, Travel Sensor Pivot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 264069 . . Sensor, Travel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 265988 . . Shaft, Force Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 266225 . . Spring, Cprsn .360 OD X .041 Wire X .750 Free Stn . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 266215 . . Cable, Extension Travel Sensor (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141162 . . Housing Plug+ Pins, (Service Kit) 14 - 18 GA . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 152568 . . Housing Plug+ Skts, (Service Kit) 20 - 24 GA . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 267601 . . Conn, Circ MS/MET 4Pin Size 14S Plug Solder . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 87
1
13
12
5 4
12
5 3
10
2
7
11
8 9
15
14
265 181-D
Figure 12-19. IR Assembly w/Mounting Bracket
Item Dia. Part

Figure 12-19. IR Assembly w/Mounting Bracket
. . 1 . . . . . . . . . . . . . . 265076 . . Sensor, Temperature IR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 265079 . . Bracket, IR Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 265081 . . Clamp, Ir Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 262553 . . Knob, Threaded Three Arm Phenolic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 265082 . . Grommet, Rbr Hi Temp 1.000 Id X 1.375 Mtg Hole .062 . . . . . . . . . . . . . . 2
. . 6 . . . . . . . . . . . . . . 265083 . . Washer, Flat .812idx1.375odx.062t Stnls Stl . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 265084 . . Collar, IR Temperature Sensor Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 265085 . . Collar, IR Temperature Sensor Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 263855 . . Ftg, Brs Elbow Qdisc 1/8 Npt X .250 Tbg Swivl . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 265116 . . Tubing, Pneumatic V−0 .250 Od X .170 ID . . . . . . . . . . . . . . . . . . . . . . . . 3.50 in.
. . 11 . . . . . . . . . . . . . . 265117 . . Tubing, Gl Acryl .258−.278 Id Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 in.
. . 12 . . . . . . . . . . . . . . 264070 . . Ftg, Air Bulkhead Panel Mtg Qdisc 1/4 Npt X .250tbg . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 267465 . . Ftg, Brs Elbow Qdisc 1/4 Npt X .250 Tbg Swivl . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 270580 . . Ring, Quartz Window Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 270581 . . Window, Quartz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 88
4
5
6
3
7
8
3
9
2
265 916-F
Figure 12-20. IR TC Control Box
Item Dia. Part

Figure 12-20. IR TC Control Box
. . 1 . . . . . . . . . . . . . . 268033 . . Label, IR Connection Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 265118 . . Cover, TC Connection Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 268037 . . Receptacle Assy, Thermocouple W/Leads IR Box . . . . . . . . . . . . . . . . . . . . 4
. . 4 . . . . . . . . . . . . . . 268044 . . Plug Assy, PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 266808 . . Enclosure, TC Connection With Rivet Nuts (Includes) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 263831 . . . . Enclosure, TC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 267916 . . . . Gasket, Epfm 3.500 X .250 X .125 Thk W/Psa . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 221493 . . . . Label, TC1−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 260811 . . . . Nut, 010−32 Hex Stl Pld Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . 6 . . . . . . . . . . . . . . 197063 . . Plug, Thermocouple Type K Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 7 . . . . . . . . . . . . . . 246958 . . Core, Ferrite 25.90mm Od X 12.80mm Id X 28.60mm Lg . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 134735 . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 266220 . . Cable,Pigtail W/14−Pin Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-271146 Page 89
. Hardware is common and not 1
265149-C
Figure 12-21. Regulator−Filter Air/Oil Separator Assembly

Item Dia. Part
Figure 12-21. Regulator−Filter Air/Oil Separator Assembly
. . 1 . . . . . . . . . . . . . . 265146 .. Filter−Reg, 1/4 Npt 5 Micron 0−30psi Auto Drain W/N . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 265147 .. Separator, Oil/Air Filter Auto Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . . 265148 .. Coupler, Air Regulator−Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 204005 .. Ftg, Plstc/Brs Elbow Qdisc 1/4 Npt X .250 Tbg Swivl . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 176518 .. Ftg, Pipe Brs Elbow St 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 265155 .. Bracket, Mtg Air Regulator−Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . . 265075 .. Bracket, Cover Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . . 265075 .. Bracket, Cover air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . *227877 .. Filter, Air Element (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . . . . . . . . . . . . . . . . *264232 .. Filter, Oil Separator (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
*Recommended Spare Parts.
OM-271146 Page 90
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

PWHT O271146g - Mil - en

Uploaded by

Copyright:

Available Formats

PWHT O271146g - Mil - en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PWHT O271146g - Mil - en

Uploaded by

Copyright:

Available Formats

OM-271146G 2016−12

Induction Heating Power Source

For product information, File: Induction Heating

Miller Electric manufactures a full line

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

Product Stock Number

July 13, 2015

MANAGER, PRODUCT DESIGN COMPLIANCE

Product Stock Number

Compliance Information Summary

Applicable regulation Directive 2014/35/EU

EMF Data for Non-thermal Health Effects

Assessment performed by: Mike Madsen Date performed: 2016-03-18

1-1. Symbol Usage

1-2. Induction Heating Hazards

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

D Follow the guidelines in the Applications Manual for the Revised

1-4. California Proposition 65 Warnings

1-5. Principal Safety Standards

1-6. EMF Information

3. Do not coil or drape cables around your body.

2-1. Signification des symboles

2-2. Dangers relatifs au soudage à l’arc

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

2-4. Proposition californienne 65 Avertissements

2-5. Principales normes de sécurité

2-6. Informations relatives aux CEM

Wear dry insulating gloves. Do not wear wet or damaged gloves.

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use ventilating fan to remove fumes.

Do not remove or paint over (cover) the label.

Do not discard product (where applicable) with general waste.

Disconnect input plug or power before working on machine.

Hazardous voltage remains on input capacitors after power is turned

Become trained and read the instructions before working on the

3-2. Miscellaneous Symbols And Definitions

A Amperage Line Connection Three Phase

Hz Hertz Read Instructions Voltage Input

I1max Rated Maximum

4-1. Serial Number and Rating Label Location

4-3. Environmental Specifications

B. Information On Electromagnetic Compatibility (EMC)

ÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ

ÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ

• Always use Miller Coolant (Miller Part Number 043810).

. Coolant will not begin to flow until it is 14° F (−10° C).

5-1. Selecting A Location

Movement ! Do not move or operate unit

Location And Airflow 3 ! Special installation may be

5-2. Dimensions And Weights

C 36.75 in. (933 mm)

* Lifting Eye Weight Rating

Reference: 2014 National Electrical Code (NEC) (including article 630)

input3 2015−01 / 803 994-E

Work like a Pro!

Input3 2015-01 / 272 715-A

5-6. Coolant Jumper Connections

Single Air-Cooled Single Liquid-Cooled