Instruction/ maintenance manual of the product Intellifire 250 Miller Electric
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Intellifire 250 Processes Description Induction Heating Power Source Induction Heating OM-184 227K 2006 − 05 V isit our website at www.MillerWelds.com File: Induction Heating.
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T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-184 227 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage safety_ihom 5/05 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-184 227 Page 2 FIRE OR EXPLOSION hazard. D Do not overheat parts and adhesive. D W atch for fire; keep extinguisher nearby . D Keep flammables away from work area. D Do not locate unit on, over , or near combustible surfaces. D Do not install unit near flammables.
OM-184 227 Page 3 1-6. EMF Information Considerations About Induction Heating And The Effects Of Low Fre- quency Electric And Magnetic Fields Th e following is a quotation from the General Conclusions Section of the U.
OM-184 227 Page 4 SECTION 2 − MESURES DE SECURITE POUR LE CHAUFF AGE P AR INDUCTION ihom_fre 8/03 PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRA VES, VOIRE MORTELLES. TENIR LES ENF ANTS A DIST ANCE. LES PORTEURS D’UN STIMULA TEUR CARDIAQUE DOIVENT PREALABLEMENT CONSUL TER LEUR MEDECIN.
OM-184 227 Page 5 DES FUMEES ET DES GAZ peuvent être dangereux pour votre santé. Le chauf fage à induction génère des fumées et des gaz. Leur inhalation peut être dangereuse pour votre santé. 1. Eloigner la tête des fumées. Ne pas respirer les fumées.
OM-184 227 Page 6 2-2. Informations concernant les champs électro-magnétiques (Information EMF) Considérations relatives au chauffage à induction et aux ef fets des champs électriques et magnétiques basse fréquence. Le texte suivant est extrait des conclusions générales Département du Congrès U.
OM-184 227 Page 7 SECTION 3 − INST ALLA TION 3-1. Specifications Output Frequency Rated Output Required Reflective Inductance Amperes Input at Rated Load Output 50 or 60 Hz, Three-Phase Overall Dimensions W eight Frequency I n d uc t ance 460 V KV A KW 10 T o 50 kHz 25 kW At 100% Duty Cycle − Max 750 A (RMS), 700 V (RMS) 2.
OM-184 227 Page 8 sb7.1* 3/93 - Ref. S-0004-A / Ref. S-0750 / Ref. ST -801 826-C 3-3. Remote 14 Receptacle RC14 Information and Connections 1 Front Panel 2 Plug 3 Threaded Collar 4 Keyway 5 Remote 14 Receptacle RC14 (See Section 3-4) T o connect to receptacle, align key- way , insert plug, and tighten threaded collar .
OM-184 227 Page 9 3-5. Connecting 3-Phase Input Power For Models With Customer Supplied Cord 803 766-A / Ref. ST-801 825-C 5/16 in 3/8 in T ools Needed: Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation.
OM-184 227 Page 10 3-6. Electrical Service Guide 60 Hz Three Phase Input V oltage 460 Input Amperes At Rated Output 39 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 45 Normal Operatin.
OM-184 227 Page 1 1 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Clean and tighten output connections. Repair or replace cracked cables and cords.
OM-184 227 Page 12 Ref. ST-801 826-A T ools Needed: 5-5. Measuring T uning Capacitor V oltage Y Significant AC voltage can remain on capacitors after unit is Off. Always check ALL capacitors as shown to be sure they have discharged before working on unit.
OM-184 227 Page 13 Ref. ST-801 826-C / Ref. 801 828-C 5-6. Ground Fault Protection Ground fault protection circuitry automatically shuts down the power source output if a potentially hazardous condition exists at the heating device connected to the power source (e.
OM-184 227 Page 14 Ref. ST-801 826-A T ools Needed: 5-7. Measuring Input Capacitor V oltage 3/8 in Y Significant DC voltage can remain on capacitors after unit is Off. Always check ALL capacitors as shown to be sure they have discharged before working on unit.
OM-184 227 Page 15 5-8. Diagnostic LED’ s Ref. ST-801 826-B 1 Diagnostic LED’s Use diagnostic LED’ s to determine operating condition of power source.
OM-184 227 Page 16 5-9. T roubleshooting T rouble Remedy No heat output. Replace building line fuse or reset circuit breaker . Secure head/coil connecting plate to power source connecting block (see Section 3-2). Check and replace Power switch if necessary .
OM-184 227 Page 17 Notes.
OM-184 227 Page 18 SECTION 6 − ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram.
OM-184 227 Page 19 204 963-A.
OM-184 227 Page 20 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. Figure 7-1. Main Assembly 801 828-F 1 Fig. 7-2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 2.
OM-184 227 Page 21 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly 1 179 245 P ANEL, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-184 227 Page 22 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Center Baffle Assembly (Fig 6-1 Item 2) 1 PM1,2 223 949 KIT , transistor IGBT module 75A 1200V 94 X 35.6MM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . PLG21,22 1 15 094 HOUSING PLUG & SKTS 2 .
OM-184 227 Page 23 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Center Baffle Assembly (Fig 6-1 Item 2)(Continued) 9 179 233 WINDTUNNEL LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte r.
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