OM-229 158N 2013−04

Processes

Induction Heating

Description

Induction Heating Power Source

Toccotron AC

Visit our website at File: Induction Heating

www.AjaxTocco.com
 TABLE OF CONTENTS

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 6
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Serial Number and Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-4. Connecting 3-Phase Input Power For 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Connecting 3-Phase Input Power For 400/460 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-6. Power Source Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-7. Remote 14 Receptacle RC14 Information and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-8. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9. I/O Receptacle RC13 Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-10. I/O Receptacle RC13 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-11. Secondary Insulation Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-12. 115 Volt AC Duplex Receptacle And Supplementary Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 − COMPONENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-2. System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3. Power Source/System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-4. Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-5. Run Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-6. Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-7. Real-Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 9 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
 TABLE OF CONTENTS

SECTION 10 − DIAGNOSTICS & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10-1. Operator Interface Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-2. Limit Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-3. Limit Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-4. Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-5. Fault Condition Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-6. System Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10-7. Removing Wrapper and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10-8. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2011-10

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 When making input connections, attach proper grounding
The symbols shown below are used throughout this manual conductor first − double-check connections.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Keep cords dry, free of oil and grease, and protected from hot metal
to avoid the hazard. The safety information given below is and sparks.
only a summary of the more complete safety information D Frequently inspect input power cord for damage or bare wiring − re-
found in the Safety Standards listed in Section 1-5. Read and place cord immediately if damaged − bare wiring can kill.
follow all Safety Standards.
D Turn off all equipment when not in use.
Only qualified persons should install, operate, maintain, and D Do not use worn, damaged, undersized, or poorly spliced cables.
repair this unit. D Do not drape cables over your body.
D Do not touch power circuit if you are in contact with the work, ground,
During operation, keep everybody, especially children, away.
or another power circuit from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
ELECTRIC SHOCK can kill. parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
Touching live electrical parts can cause fatal shocks D Keep all panels and covers securely in place.
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine SIGNIFICANT DC VOLTAGE exists in inverter power
internal circuits are also live when power is on. Incorrectly installed or sources AFTER removal of input power.
improperly grounded equipment is a hazard.
D Turn Off inverter, disconnect input power, and discharge input
D Do not touch live electrical parts. capacitors according to instructions in Maintenance Section before
D Enclose any connecting bus bars and coolant fittings to prevent touching any internal parts.
unintentional contact.
FUMES AND GASES can be hazardous.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or Induction Heating of certain materials, adhesives,
covers big enough to prevent any physical contact with the work or and fluxes can produce fumes and gases. Breathing
ground. these fumes and gases can be hazardous to your
D Additional safety precautions are required when any of the follow- health.
ing electrically hazardous conditions are present: in damp locations D Keep your head out of the fumes. Do not breathe the fumes.
or while wearing wet clothing; on metal structures such as floors, D If inside, ventilate the area and/or use local forced ventilation to re-
gratings, or scaffolds; when in cramped positions such as sitting, move fumes and gases.
kneeling, or lying; or when there is a high risk of unavoidable or ac-
D If ventilation is poor, wear an approved air-supplied respirator.
cidental contact with the workpiece or ground. For these
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not D Read and understand the Material Safety Data Sheets (MSDSs)
work alone! and the manufacturer’s instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.
D Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA 29 CFR D Work in a confined space only if it is well ventilated, or while wearing
1910.147 (see Safety Standards). an air-supplied respirator. Always have a trained watchperson near-
by. Fumes and gases from heating can displace air and lower the
D Use only nonconductive coolant hoses with a minimum length of 18 oxygen level causing injury or death. Be sure the breathing air is
inches (457 mm) to provide isolation. safe.
D Properly install, ground, and operate this equipment according to its D Do not heat in locations near degreasing, cleaning, or spraying oper-
Owner’s Manual and national, state, and local codes. ations. The heat can react with vapors to form highly toxic and
D Always verify the supply ground − check and be sure that input pow- irritating gases.
er cord ground wire is properly connected to ground terminal in D Do not overheat coated metals, such as galvanized, lead, or
disconnect box or that cord plug is connected to a properly grounded cadmium plated steel, unless the coating is removed from the
receptacle outlet. heated area, the area is well ventilated, and while wearing an air-
supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if overheated. See coating MSDS
for temperature information.

OM-229 158 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.
D Do not install unit near flammables.
D Keep metal jewelry and other metal personal items away from
D Do not operate where the atmosphere may contain flammable head/coil during operation.
dust, gas, or liquid vapors (such as gasoline).
D To handle hot parts, use proper tools and/or wear heavy, insu-
D After completion of work, inspect area to ensure it is free of lated welding gloves and clothing to prevent burns.
sparks, glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.

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

FALLING EQUIPMENT can injure. STATIC (ESD) can damage PC boards.

D Use handle and have person of adequate D Put on grounded wrist strap BEFORE handling
physical strength lift unit. boards or parts.
D Move unit with hand cart or similar device. D Use proper static-proof bags and boxes to
D For units without a handle, use equipment of store, move, or ship PC boards.
adequate capacity to lift and support unit.
D Keep equipment (cables and cords) away from moving vehicles H.F. RADIATION can cause interference.
when working from an aerial location.
D If using lift forks to move unit, be sure forks are long enough to D High-frequency (H.F.) can interfere with radio
extend beyond opposite side of unit. navigation, safety services, computers, and
D Follow the guidelines in the Applications Manual for the Revised communications equipment.
NIOSH Lifting Equation (Publication No. 94−110) when manu- D Have only qualified person familiar with electronic equipment per-
ally lifting heavy parts or equipment. form this installation.
D The user is responsible for having a qualified electrician promptly
FLYING METAL OR DIRT can injure eyes. correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
D Wear approved safety glasses with side
ment at once.
shields or wear face shield.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut.
MOVING PARTS can injure.
READ INSTRUCTIONS.
D Keep away from moving parts such as fans.
D Read and follow all labels and the Owner’s
D Keep all doors, panels, covers, and guards
Manual carefully before installing, operating, or
closed and securely in place.
servicing unit. Read the safety information at
D Have only qualified persons remove doors, panels, covers, or the beginning of the manual and in each
guards for maintenance and troubleshooting as necessary. section.
D Reinstall doors, panels, covers, or guards when maintenance is D Use only genuine replacement parts from the manufacturer.
finished and before reconnecting input power. D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices. BATTERY EXPLOSION can injure.
D Wearers of Pacemakers and other Implanted D Do not use induction equipment to charge bat-
Medical Devices should keep away. teries or jump start vehicles unless it has a bat-
D Implanted Medical Device wearers should consult their doctor tery charging feature designed for this purpose.
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

OVERUSE can cause OVERHEATING

D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.

OM-229 158 Page 2

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, Ontario, Canada L4W 5NS (phone: website: www.csa-international.org).
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 30333 (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). Welding current creates an EMF field around ing circuit as possible.
the welding circuit and welding equipment. EMF fields may interfere with
some medical implants, e.g. pacemakers. Protective measures for per- 5. Connect work clamp to workpiece as close to the weld as
sons wearing medical implants have to be taken. For example, restrict possible.
access for passers−by or conduct individual risk assessment for weld-
ers. All welders should use the following procedures in order to minimize 6. Do not work next to, sit or lean on the welding power source.
exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If
to one side and away from the operator.
cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM-229 158 Page 3

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom 2011−10_fre

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 dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

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

D Installer le poste correctement et le mettre à la terre convenable-
Les symboles présentés ci-après sont utilisés tout au long du ment selon les consignes du manuel de l’opérateur et les normes
présent manuel pour attirer votre attention et identifier les ris-
nationales, provinciales et locales.
ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assu-
danger. Les consignes de sécurité présentées ci-après ne font rer que le fil de terre du cordon d’alimentation est bien raccordé à la
que résumer l’information contenue dans les normes de sécu- borne de terre du sectionneur ou que la fiche du cordon est raccor-
rité énumérées à la section 2-5. Veuillez lire et respecter toutes dée à une prise correctement mise à la terre.
ces normes de sécurité. D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et revérifier les connexions.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chau-
des.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants. D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à
nu peut entraîner la mort.
UNE DÉCHARGE ÉLECTRIQUE peut
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
entraîner la mort.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
Le contact de composants électriques peut provo-
quer des accidents mortels ou des brûlures graves. D Ne pas enrouler les câbles autour du corps.
Le circuit électrique et les barres collectrices ou les
connexions de sortie sont sous tension lorsque D Ne pas toucher le circuit électrique si l’on est en contact avec la piè-
l’appareil fonctionne. Le circuit d’alimentation et les circuits internes ce, la terre ou le circuit électrique d’une autre machine.
de la machine sont également sous tension lorsque l’alimentation est D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
sur marche. Des équipements installés ou reliés à la borne de terre de champ les pièces endommagées. Entretenir l’appareil conformé-
manière incorrecte sont dangereux. ment à ce manuel.
D Ne pas toucher aux pièces électriques sous tension. D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D Protéger toutes les barres collectrices et les raccords de refroidis- D S’assurer que tous les panneaux et couvercles sont correctement
sement pour éviter de les toucher par inadvertance. en place.
D Porter des gants isolants et des vêtements de protection secs et
sans trous. Il reste une TENSION DC NON NÉGLIGEABLE dans
D S’isoler de la pièce à couper et du sol en utilisant des housses ou les sources de soudage onduleur UNE FOIS le
des tapis assez grands afin d’éviter tout contact physique avec la moteur coupé.
pièce à couper ou le sol. D Avant de toucher des organes internes, couper l’onduleur,
D D’autres consignes de sécurité sont nécessaires dans les condi- débrancher l’alimentation et décharger les condensateurs
tions suivantes : risques électriques dans un environnement d’alimentation conformément aux instructions indiquées dans la
humide ou si l’on porte des vêtements mouillés ; sur des structures partie maintenance.
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
LES FUMÉES ET LES GAZ peuvent
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, voir ANSI Z49.1 énuméré dans les nor- être dangereux.
mes de sécurité. En outre, ne pas travailler seul !
Le chauffage à induction de certains matériaux,
D Couper l’alimentation d’entrée avant d’installer l’appareil ou d’effec- adhésifs et flux génère des fumées et des gaz. Leur
tuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation selon inhalation peut être dangereuse pour votre santé.
la norme OSHA 29 CFR 1910.147(se reporter aux Principales nor-
mes de sécurité). D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces
vapeurs.
D N’utiliser que des tuyaux de refroidissement non conducteurs ayant
une longueur minimale de 457 mm pour garantir l’isolation.

OM-229 158 Page 5

D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Stocker des produits inflammables hors de la zone de travail.
niveau de l’arc pour l’évacuation des fumées et des gaz. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs ap- inflammables.
prouvé. D Ne pas installer l’appareil à proximité de produits inflammables.
D Lire et comprendre les spécifications de sécurité des matériaux D Ne pas faire fonctionner l’appareil si l’air ambiant est chargé de parti-
(MSDS) et les instructions du fabricant concernant les adhésifs, les cules, gaz, ou vapeurs inflammables (vapeur d’essence, par
flux, les métaux, les consommables, les revêtements, les net- exemple).
toyants et les dégraisseurs.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en d’étincelles incandescentes ni de flammes.
portant un respirateur. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz provenant du D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
chauffage peuvent déplacer l’air, abaisser le niveau d’oxygène et Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des lésions ou des accidents mortels. S’assurer que l’air
ambiant ne présente aucun danger. LE CHAUFFAGE PAR INDUCTION peut
D Ne pas chauffer dans des endroits se trouvant à proximité d’opéra- provoquer des brûlures.
tions de dégraissage, de nettoyage ou de pulvérisation. La chaleur
peut réagir en présence de vapeurs et former des gaz hautement D Ne pas toucher des parties chaudes à mains
toxiques et irritants. nues.
D Ne pas surchauffer des métaux munis d’un revêtement tels que D Laisser refroidir les composants ou équipe-
l’acier galvanisé, plaqué au plomb ou au cadmium, à moins que le ments avant de les manipuler.
revêtement ne soit enlevé de la zone chauffée, que la zone soit bien
ventilée et, si nécessaire, en portant un respirateur. Les revête- D Ne pas toucher ou manipuler la tête/l’enroulement à induction pen-
ments et tous les métaux contenant ces éléments peuvent dégager dant le fonctionnement.
des fumées toxiques s’ils sont surchauffés. Voir les informations D Tenir les bijoux et autres objets personnels en métal éloignés de la
concernant la température dans les spécifications de revêtement tête/de l’enroulement pendant le fonctionnement.
MSDS. D Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
Risque D’INCENDIE OU D’EXPLO- pour éviter les brûlures.
SION.
D Ne pas surchauffer les composants .
D Attention aux risques d’incendie: tenir un ex-
tincteur à proximité.

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

maintenance

LA CHUTE DE L’ÉQUIPEMENT peut DES ORGANES MOBILES peuvent

provoquer des blessures. provoquer des blessures.
D Utiliser la poignée et demander à une personne D S’abstenir de toucher des organes mobiles tels
ayant la force physique nécessaire pour soule- que des ventilateurs.
ver l’appareil. D Maintenir fermés et verrouillés les portes, pan-
D Déplacer l’appareil à l’aide d’un chariot ou d’un neaux, recouvrements et dispositifs de protec-
engin similaire. tion.
D Pour les unités sans poignée, utiliser un équipement de levage de Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
capacité suffisante pour lever l’appareil.
peuvent affecter les implants médicaux.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur. D Les porteurs de stimulateurs cardiaques et
D En utilisant des fourches de levage pour déplacer l’unité, s’assu- autres implants médicaux doivent rester à
rer que les fourches sont suffisamment longues pour dépasser du distance.
côté opposé de l’appareil. D Les porteurs d’implants médicaux doivent consulter leur
D Suivre les consignes du Manuel des applications pour l’équation médecin et le fabricant du dispositif avant de s’approcher de la
de levage NIOSH révisée (Publication Nº94−110) lors du levage zone où se déroule du soudage à l’arc, du soudage par points, du
manuelle de pièces ou équipements lourds. gougeage, de la découpe plasma ou une opération de chauffage
par induction.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des
blessures dans les yeux.
D Porter des lunettes de sécurité à coques latéra-
les ou un écran facial.

OM-229 158 Page 6

 D L’utilisateur est tenu de faire corriger rapidement par un électricien
L’EMPLOI EXCESSIF peut SUR- qualifié les interférences résultant de l’installation.
CHAUFFER L’ÉQUIPEMENT. D Si le FCC signale des interférences, arrêter immédiatement l’appa-
reil.
D Prévoir une période de refroidissement
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Réduire le courant de sortie ou le facteur de mar-
che avant de recommencer le chauffage. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence.
D Respecter le cycle opératoire nominal.
LIRE LES INSTRUCTIONS.
LES CHARGES ÉLECTROSTATIQUES D Lire et appliquer les instructions sur les
peuvent endommager les circuits im- étiquettes et le Mode d’emploi avant
primés. l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
D Établir la connexion avec la barrette de terre début du manuel et dans chaque section.
AVANT de manipuler des cartes ou des pièces. D N’utiliser que les pièces de rechange recommandées par le
D Utiliser des pochettes et des boîtes antistati- constructeur.
ques pour stocker, déplacer ou expédier des D Effectuer l’entretien en respectant les manuels d’utilisation,
cartes PC. les normes industrielles et les codes nationaux, d’état et locaux.
LE RAYONNEMENT HAUTE FRÉ- L’EXPLOSION DE LA BATTERIE
QUENCE (HF) risque de provoquer peut provoquer des blessures.
des interférences.
D Ne pas utiliser l’appareil de soudage pour
D Le rayonnement haute fréquence (HF) peut charger des batteries ou faire démarrer
provoquer des interférences avec les équipe- des véhicules à l’aide de câbles de démarrage,
ments de radio-navigation et de communication, sauf si l’appareil dispose d’une fonctionnalité
les services de sécurité et les ordinateurs. de charge de batterie destinée à cet usage.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.

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 mal- cancérogène ainsi que provoquant des malformations
formations 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.csa-international.org).
W117.2, from Canadian Standards Association, Standards Sales, 5060 Safe Practice For Occupational And Educational Eye And Face Protec-
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: tion, ANSI Standard Z87.1, from American National Standards Institute,
800-463-6727, website: www.csa-international.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 30333 (phone: 1-800-232-4636, website: www.cdc.gov/
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone 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).

OM-229 158 Page 7

2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs 4. Maintenir la tête et le torse aussi loin que possible du matériel du
électromagnétiques (CEM) à certains endroits. Le courant de soudage circuit de soudage.
crée un CEM autour du circuit et du matériel de soudage. Les CEM 5. Connecter la pince sur la pièce aussi près que possible de la
peuvent créer des interférences avec certains implants médicaux soudure.
comme des stimulateurs cardiaques. Des mesures de protection pour
6. Ne pas travailler à proximité d’une source de soudage, ni
les porteurs d’implants médicaux doivent être prises: Limiter par s’asseoir ou se pencher dessus.
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent 7. Ne pas souder tout en portant la source de soudage ou le
appliquer les procédures suivantes pour minimiser l’exposition aux dévidoir.
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.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

OM-229 158 Page 8

 SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

. Some symbols are found only on CE products.

Disconnect input plug or power before working on machine.

Safe5 2012−05

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

Safe20 2012−05

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

Safe73 2012−07

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-229 158 Page 9

 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

? 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

V Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
V Safe43 2012−05

Become trained and read the instructions before working on the

machine or heating.

Safe85 2012−06

Connect green or green/yellow grounding conductor to ground

terminal.
Connect input conductors (L1, L2 And L3) to line terminals.
Safe86 2012−06

OM-229 158 Page 10

3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.

A Amperes
V Volts Alternating Current
X Duty Cycle

IP Degree Of
Protection Hz Hertz Circuit Protector Output

Increase Line Connection I1 Primary Current I2 Rated Current

Three Phase Static

Frequency Con-
U1 Primary Voltage U2 Load Voltage Read Instructions verter-Transform-
er-Frequency Con-
verter

Rated Maximum Maximum Power

I1max Supply Current P1max Consumption
Three Phase Percent

Remote Panel/Local High Temperature Voltage Input

Off On

OM-229 158 Page 11

 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

Amperes Input at
Required Rated Load Output
Output 50 or 60 Hz, Overall
Rated Output Reflective Weight
Frequency Three-Phase Dimensions
Inductance
400 V 460 V 575 V kVA kW
Length: 36-3/4 in.
(993 mm)
35 kW At 100% Duty Cycle
5 To 30 2.5 To 50 Width: 21-1/2 in. 227 lb
700 A (RMS), 60 A 50 A 40 A 39 37
kHz μh (546 mm) (103 kg)
700 V (RMS)
Height: 29 in.
(737 mm)
*While idling

4-3. Environmental Specifications

A. IP Rating
IP Rating Storage Temperature Range
IP23CM
This equipment is designed for outdoor use. It may be stored, but is -40 to 122 °F (-40 to 50°C)
not intended to be used outside during precipitation unless sheltered.

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 IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 8,911,817 at the interface
point between the user’s supply and the public system. 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 equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 8,911,817.

OM-229 158 Page 12

 SECTION 5 − INSTALLATION
5-1. Selecting A Location
! Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Movement Section 20.
1. Lifting Eye
2. Lifting Forks
Use lifting eye or lifting forks to
1 move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3. Line Disconnect Device
Locate unit near correct input
power supply.
OR
2

Location And Airflow

12 in.
(305 mm)

18 in.
(460 mm)

12 in.
(305 mm)

18 in.
(460 mm)

804 596-A

OM-229 158 Page 13

5-2. Tipping
! Do not move or operate unit
where it could tip.

5-3. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions 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
Three 60 Hz Three Phase
Phase
Input Voltage (V) 400 460 575
Input Amperes (A) At Rated Output 60 50 40
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 1

Circuit Breaker 1, Time-Delay Fuses 2 70 61 45

Normal Operating Fuses 3 80 70 60
Min Input Conductor Size In AWG 4 6 8 8
254 214 334
Max Recommended Input Conductor Length In Feet (Meters)
(77) (65) (102)
Min Grounding Conductor Size In AWG 4 8 8 10

Reference: 2011 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.

OM-229 158 Page 14

Notes

OM-229 158 Page 15

5-4. Connecting 3-Phase Input Power For 460/575 Volt Models

GND/PE Earth Ground

3
8

10

6
5 4
3

Tools Needed:
3/8 in.
3/8 in.

input3 2012−05 − 804 598-B

OM-229 158 Page 16

5-4. Connecting 3-Phase Input Power For 460/575 Volt Models (Continued)

! Installation must meet all National and Welding Power Source Input Power Con- Disconnect Device Input Power Connec-
Local Codes − have only qualified per- nections tions
sons make this installation. 2. Strain Relief 7. Disconnect Device (switch shown in
! Disconnect and lockout/tagout input OFF position)
Route conductors (cord) through strain relief
power before connecting input con- and tighten screws. 8. Disconnect Device (Supply) Grounding
ductors from unit. Follow established Terminal
3. Machine Grounding Terminal
procedures regarding the installation Connect green or green/yellow grounding
and removal of lockout/tagout 4. Green Or Green/Yellow Grounding conductor to disconnect device grounding ter-
devices. Conductor minal first.
! Make input power connections to the Connect green or green/yellow grounding 9. Disconnect Device Line Terminals
welding power source first. conductor to welding power source grounding
terminal first. Connect input conductors L1 (U), L2 (V) And
! Always connect green or green/yellow L3 (W) to disconnect device line terminals.
conductor to supply grounding termi- 5. Welding Power Source Line Terminals
10. Over-Current Protection
nal first, and never to a line terminal. 6. Input Conductors L1 (U), L2 (V) And L3
Select type and size of over-current protection
. The circuitry in this unit automatically
(W)
using Section 5-3 (fused disconnect switch
adapts the power source to the primary Connect input conductors L1 (U), L2 (V) and shown).
voltage being applied. Check input L3 (W) to welding power source line terminals.
Close and secure door on line disconnect de-
voltage available at site. This unit can be Close and secure access door on welding vice. Follow established lockout/tagout pro-
connected to either 460 or 575 VAC input power source. cedures to put unit in service.
power.
See rating label on unit and check input volt-
age available at site.
1. Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-3. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.

input3 2012−05

OM-229 158 Page 17

5-5. Connecting 3-Phase Input Power For 400/460 Volt Models

3
= GND/PE Earth Ground
8

10

L1
L2 6
4 L3
9

5 2
3 4

Tools Needed:
3/8 in.
3/8 in.

input3 2012−05 − Ref. 804 430-A / Ref. 804 598-A

OM-229 158 Page 18

5-5. Connecting 3-Phase Input Power For 400/460 Volt Models (Continued)

! Installation must meet all National and Select size and length of conductors using Disconnect Device Input Power Connec-
Local Codes − have only qualified per- Section 5-3. Conductors must comply with tions
sons make this installation. national, state, and local electrical codes. If
applicable, use lugs of proper amperage 7. Disconnect Device (switch shown in
! Disconnect and lockout/tagout input capacity and correct hole size. OFF position)
power before connecting input con-
ductors from unit. Follow established Welding Power Source Input Power Con- 8. Disconnect Device (Supply) Grounding
procedures regarding the installation nections
Terminal
and removal of lockout/tagout 2. Strain Relief
devices. Connect green or green/yellow grounding
Route conductors (cord) through strain relief
! Make input power connections to the and tighten screws. conductor to disconnect device grounding ter-
welding power source first. minal first.
3. Machine Grounding Terminal
! Always connect green or green/yellow 4. Green Or Green/Yellow Grounding 9. Disconnect Device Line Terminals
conductor to supply grounding termi- Conductor
nal first, and never to a line terminal. Connect input conductors L1 (U), L2 (V) And
Connect green or green/yellow grounding L3 (W) to disconnect device line terminals.
. The circuitry in this unit automatically conductor to welding power source grounding
adapts the power source to the primary terminal first.
10. Over-Current Protection
voltage being applied. Check input 5. Welding Power Source Line Terminals
voltage available at site. This unit can be
6. Input Conductors L1 (U), L2 (V) And L3 Select type and size of over-current protection
connected to either 400 or 460 VAC input
(W) using Section 5-3 (fused disconnect switch
power.
shown).
See rating label on unit and check input volt- Connect input conductors L1 (U), L2 (V) and
age available at site. L3 (W) to welding power source line terminals.
Close and secure door on line disconnect de-
1. Input Power Conductors (Customer Close and secure access door on welding vice. Follow established lockout/tagout pro-
Supplied Cord) power source. cedures to put unit in service.

input3 2012−05

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-229 158 Page 19

 5-6. Power Source Output Connections
1. Output Bus Bars
1 Use supplied 1/4-20 nuts to make
electrical connections to the output
bus bars as required by the specific
application.

804 597-A

OM-229 158 Page 20

5-7. Remote 14 Receptacle RC14 Information and Connections
1. Plug
2. Threaded Collar
3. Keyway
4. Remote 14 Receptacle RC14
3 (See Section 5-8)
To connect to receptacle, align key-
way, insert plug and tighten
threaded collar.
A J 4
K I
B
C L N H
D M G
E F

804 597-A

5-8. 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 Not used.
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 Not used.
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-229 158 Page 21

 5-9. I/O Receptacle RC13 Information And Connections
1. Plug
3
2. Threaded Collar
3. I/O Receptacle RC13 (See
Section 5-10)
To connect to receptacle, insert
plug and tighten threaded collar.

804 597-A

5-10. I/O Receptacle RC13 Socket Information

Socket No. Socket Information
1 Incycle Common
2 Incycle Normally Closed
3 Incycle Normally Open
4 Auxiliary Common
5 Auxiliary Normally Closed
6 Auxiliary Normally Open
7 Limit Common
8 Limit Normally Closed
9 Limit Normally Open
10 Not Used
External Interrupt − This works like an interlock (if enabled via the setup screens). This could
be used as a coolant flow switch or for other purposes. Contact closure to socket 12 by flow
11 switch indicates coolant is flowing in the induction heating system if enabled on the set up
screen (see Section 7-3). Absence of contact closure will prevent starting heating cycle, or
stop heating cycle and provide an error message on the pendant display.
12 +24 volts DC
13 +24 volts DC
Remote Enable − This is the external contact closure to enable output when in Remote mode.
Maintained contact closure to socket 13 starts the heating cycle if enabled on the set up
14
screen (see Section 7-3). Opening the contact closure or pressing the STOP button on the
pendant stops the heating cycle.

OM-229 158 Page 22

5-11. Secondary Insulation Protection
! Connect ground lead(s)
between the workpiece and
power source to provide
proper secondary insulation
protection from a short in the
output circuit.
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 coil causing the conductor to
come into contact with the workpiece
or a heating coil touches the
workpiece causing a short in the
output circuit).
This circuitry must be enabled before
this feature is available. See Section
7-3.
1. Receptacles
2. Plug
To connect plug, align key with key-
way, insert end into receptacle, and
rotate plug until tight.
3. Customer−Supplied Handle
4. Customer−Supplied 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
workpiece.
1 2

804 598-A / Ref. 801 828-C

OM-229 158 Page 23

 5-12. 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. Maximum
output from receptacle is 2.5 am-
peres.
CB1 protects 115 volt receptacle
1 RC1 from overload. If CB1 opens,
RC1 does not work.

804 597-A

OM-229 158 Page 24

 SECTION 6 − COMPONENTS AND CONTROLS
6-1. Controls

7 8 10 12 13 14
9 11
6

5
15

4
16
2
3

17
18
19

804 599-A

. When a control panel button is pushed 6. Degrees C LED 13. Cursor Button
the yellow lamp lights to indicate ac- Power source temperature display in de- Use button to move selection cursor in the
tivation. grees C when lit. 4 x 40 LCD display (item 14.).
1. Power Switch 7. KW Seconds Scaled LEDs 14. 4 x 40 LCD Display
Multiply displayed value by value of lit LED. Displays programming, runs status, pa-
Use switch to turn power source On and rameter, fault and limit conditions, and trou-
Off. 8. Fault LED bleshooting guide.
2. Power Source Temperature Display LED lights to indicate a system fault condi- 15. Increase Button
tion.
Provides temperature display of the domi- Use button to increase value as required.
nant heat sink. 9. Limit LED
16. Decrease Button
LED lights to indicate a system limit condi-
3. KW Output Use button to decrease value as required.
tion.
Provides display of actual power output val- 17. Parameter Button
10. Heat On LED
ue. Use button to display “real time” power
LED lights to indicate the power source out- source operating parameters.
4. KW Seconds put is energized.
18. Run Status Button
Provides display of energy output value. 11. Run Button
Use button to display “real time” operating
5. Command Setting Use button to run a heating process. status.
Displays power level programmed by oper- 12. Stop Button 19. Program Button
ator. Use button to stop a heating process. Use button to program the process control.

OM-229 158 Page 25

 SECTION 7 − SETUP AND OPERATION
7-1. Safety Equipment
Wear the following during
operation:
1 2
1. Dry, Insulating Gloves
2. Safety Glasses With Side
Shields
DO NOT wear rings, watches, or
other metallic items during opera-
tion. sb3.1* 1/94

7-2. System Description

The Toccotron AC is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal temper-
atures reach or exceed specific set limits (see Section 10).

7-3. Power Source/System Setup

kW
To view the System Setup screen, simultaneously press the Parameters V
A and Program buttons and the following screen appears on
Hz

the display:

Time Resolution: Seconds SETUP1

KW Second Alarm: No Min: 0 Max: 9999
KW Second Scale: x1 ExtInterrupt: YES
Remote Enable..: No

System Lock.: No SETUP2

Control Mode: Timed Command: Power
Max KW......: 35 Degree Units: _F
Backlight...: Yes Isolation Detect: Yes

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 setup feature.

Possible selections Setup 1:

Time Resolution in seconds − 0.1 second increments

KW Second Alarm − Yes/No Minimum: 0−9999, Maximum: 0−9999

KW Second Scale − x1, x10, x100 External Interrupt − Yes/No

Remote Enable − Yes/No

OM-229 158 Page 26

 Possible selections Setup 2:

System Lock − Yes/No

Control Mode − Timed / Remote / Manual Command − Power / Voltage / Current

Max KW: 1−35 Degree Units − °F / °C

Backlight − Yes/No Isolation Detect − Yes/No

Time Resolution − press the Increase or Decrease button to select the desired time resolution.

S The factory default is seconds.

KW Second Alarm − press the Increase or Decrease button to select the desired KW Second Alarm.

S The factory default is No.

S If KW Second Alarm is enabled, set Minimum and Maximum values.

KW Second Scale − press the Increase or Decrease button to select the desired KW Second Scale.

S The factory default is x1.

External Interrupt − press the Increase or Decrease button to enable or disable this feature.

S The factory default is Yes.

Remote Enable − press the Increase or Decrease button to select a remote command source.

S The factory default is No.

System Lock − press the Increase or Decrease button to lock or unlock the operator interface to

prevent tampering with any programs. Yes indicates the system is locked, and No indicates the system is
unlocked.

S The factory default is No (unlocked).

Control Mode − press the Increase or Decrease button to select the desired method of system control. For more de-

tails about methods of control, see Section 7-4.

S The factory default is time based control.

Command − press the Increase or Decrease button to select the desired command mode.

S The factory default is Power.

Max KW − press the Increase or Decrease button to adjust the maximum power source output.

S The factory default is 35 kW.

Degree Units − press the Increase or Decrease buttons to select temperature units. Selection will drive the °C indicator

LED.

S The factory default is °C.

OM-229 158 Page 27

Backlight − press the Increase or Decrease button to turn LCD display backlight On or Off.

S The factory default is On.

Isolation Detect− press the Increase or Decrease button to enable or disable this feature.

S The factory default is Yes.

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.

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.

7-4. Programming
Programming allows the operator to setup a program for a particular heating process. The selections available are Timed, Remote, or Manual.
7-4-1. Time-Based Control
Time-based control operates the system and controls the heating process based on programmed time and power, voltage, current, or energy values.
An auxiliary relay can also be programmed to interface with a PLC or similar controller.

Press the Program button to access the programming mode. Use the cursor button to move the cursor between Program, Segement, Type, Power,
and Time.

Mode...: Timed
Program: 1 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:

Program: 1 − 8 Segement: 1 − 10

Type: Power Level, Slope, KW Seconds, End

Power: 0.0 − 35 or Voltage: 0.0 − 700, or Current: 0.0 − 700 Time: 00:00:00 − 99:59:59 or infinity

OM-229 158 Page 28

 7-4-2. Remote Control
If Remote was selected as the control mode in the setup window, 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 infinity.

7-4-3. 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:

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 or infinity.

7-4-4. Auxiliary Relay

The Auxiliary Relay is fully programmable for use in controlling auxiliary equipment such as lamps and solenoids and can operate after the heating cycle
ends. The delay time and on time are set during programming.

Possible selections:

Enable − Yes/No

Delay Time − 00:00:00 − 99:59:59 Or Infinity

On Time − 00:00:00 − 99:59:59 Or Infinity

Auxiliary Relay
Enable.....: No
Delay Time.: 00:00:00
On Time....: 00:00:00

7-5. Run Status

Run status allows the operator to check status of a program during in-process heating. Depending on the control mode (Timed, Remote, or Manual),
different style screens appear on the display. Run status is for monitoring purposes only and has no selectable or changeable parameters.

OM-229 158 Page 29

 7-5-1. Time Based Control

Mode...: Timed Segment KWS:

Program: 1 Segment: 1 0 x1
Type...: End
Power..: 0.0 KW SegmentTime: 00:00:00

Mode displays the control mode. Also displayed are the present program number, program segment, KW seconds, Segment type, current power
level and elapsed time of the current segment.

7-5-2. Remote Control

Mode.....: Remote
Power....: 0.0 KW
CycleTime: 00:00:00
Status...: Stopped

During active operation, Power shows the actual power delivered from the power source, Cycle Time shows the elapsed time 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.

7-5-3. Manual Control

Mode.....: Manual
Power....: 0.0 KW
CycleTime: 00:00:00
Status...: Stopped

During active operation, Power shows the actual power delivered from the power source, Cycle Time shows the elapsed time in 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. 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. The Parameters screen is for monitoring purposes only and has no
selectable or changeable parameters. Once the cycle has ended or the Stop button has been pressed, the Power, Voltage, and Current values return to
zero (0). To review the latest run parameter, press and hold the Parameters button.

OM-229 158 Page 30

 Power....: 0.0 KW
Current..: 0 A
Voltage..: 0 V
Frequency: 4.5 KHz CycleTime: 00:00:00

7-7. 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:

TOCCOtron AC
Firmware Revision OEM 0.52
Copyright (c) 2006
MEM

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:

S The Stop button indicator LED illuminates to indicate no heating cycle is in process.

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 7-3), 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.

S Press the Program button and the yellow indicator LED will illuminate. The display will change to

show the current mode of operation or the current segment of a Timed 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.

OM-229 158 Page 31

 S Press the Run button to resume program operation and the yellow indicator LED will illuminate.

S Press the Stop button to end the program.

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
Every Section 5-6
3
Months

l Damaged or Unreadable ~ Output Bus Bar Con- ~ Ground Sense Lead Re- ~ Operator Interface Over-
Labels tacts ceptacles lay

nlCracked Cables
Every Section
6 10-8
Months

~ Inside Unit

OM-229 158 Page 32

 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

OM-___ - Date, safety_ihtm 2011-10

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 FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
D Be careful not to short metal tools, parts, or
Only qualified persons should service, test, maintain, and re-
pair this unit. wires together during testing and servicing.

During servicing, keep everybody, especially children, away.

INDUCTION HEATING can burn.
ELECTRIC SHOCK can kill. D Do not touch hot parts bare handed.
D Allow cooling period before handling parts on
D Do not touch live electrical parts. equipment.
D Turn Off induction heating power source and D Do not touch or handle induction head/coil during operation.
disconnect and lockout input power using line
disconnect switch, circuit breakers, or by removing plug from recep- D Keep metal jewelry and other metal personal items away from
tacle, or stop engine before servicing unless the procedure specifi- head/coil during operation.
cally requires an energized unit. D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
D Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended. EXPLODING PARTS can injure.
D If this procedure requires an energized unit, have only personnel
D Failed parts can explode or cause other parts to
familiar with and following standard safety practices do the job.
explode when power is applied to inverters.
D When testing a live unit, use the one-hand method. Do not put both D Always wear a face shield and long sleeves
hands inside unit. Keep one hand free. when servicing inverters.
D Disconnect input power conductors from deenergized supply line
BEFORE moving an induction heating power source.
SHOCK HAZARD from testing.
SIGNIFICANT DC VOLTAGE exists in inverter
power sources AFTER removal of input power. D Turn Off induction heating power source be-
fore making or changing meter lead connec-
D Turn Off inverter, disconnect input power, and discharge input tions.
capacitors according to instructions in Troubleshooting Section be- D Use at least one meter lead that has a self-
fore touching any parts. retaining spring clip such as an alligator clip.
D Read instructions for test equipment.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling FALLING EQUIPMENT can injure.
boards or parts.
D Use proper static-proof bags and boxes to D Use lifting eye to lift unit only, NOT running
store, move, or ship PC boards. gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
FIRE OR EXPLOSION hazard. D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Do not place unit on, over, or near combustible D Follow the guidelines in the Applications Manual for the Revised
surfaces. NIOSH Lifting Equation (Publication No. 94−110) when manu-
D Do not service unit near flammables. ally lifting heavy parts or equipment.

OM-229 158 Page 33

 MOVING PARTS can injure. H.F. RADIATION can cause interference.

D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio
D Have only qualified persons remove doors, navigation, safety services, computers, and
panels, covers, or guards for maintenance and communications equipment.
troubleshooting as necessary. D Have only qualified persons familiar with
D Keep hands, hair, loose clothing, and tools away from moving electronic equipment install, test, and service
parts. H.F. producing units.
D Reinstall doors, panels, covers, or guards when maintenance is D The user is responsible for having a qualified electrician prompt-
finished and before reconnecting input power. ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices. D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
D Wearers of Pacemakers and other Implanted spark gaps at correct setting, and use grounding and shielding to
Medical Devices should keep away from serv- minimize the possibility of interference.
icing areas until consulting their doctor and the
device manufacturer. READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
OVERUSE can cause OVERHEATING.
D Consult the Owner’s Manual for welding safety
D Allow cooling period; follow rated duty cycle. precautions.
D Reduce current or reduce duty cycle before us- D Use only genuine replacement parts from the manufacturer.
ing induction heating equipment again. D Read and follow all labels and the Technical Manual carefully be-
fore installing, operating, or servicing unit. Read the safety in-
D Do not block or filter airflow to unit.
formation at the beginning of the manual and in each section.

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 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, restrict access for passers−by or conduct individual risk as-
sessment for welders. All welders should use the following procedures 6. Do not work next to, sit or lean on the welding power source.
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.
1. Keep cables close together by twisting or taping them, or using a
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM-229 158 Page 34

 SECTION 10 − DIAGNOSTICS & TROUBLESHOOTING
The Toccotron AC 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

804 599-A

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.

10-2. Limit Conditions

A limit condition indicates that the system 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 describ-

ing 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.

OM-229 158 Page 35
Pressing the Decrease button will acknowledge the limit and continue operation with the existing setup. 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
L07: Output Voltage Limit Tighten blanket against pipe surface
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
L12: Power Source Overtemp Limit Check for blocked vents
Clean wind tunnel heat sinks

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
F58: Output Voltage Fault Service required
F59: Output Current Fault Service required

OM-229 158 Page 36

 Fault Condition Additional Information
F62: Isolation Fault Check for exposed conductor
Clean for moisture on cables
F63:Line Voltage Fault Check line voltage
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
Decrease coil space
F67: Over Frequency Fault Verify heating cable properly wrapped
Verify material being heated is magnetic
F70: Internal Communication Fault Service required
F71: Internal Thermistor Fault Service required
F73: Decoupled/Open Coil Service required
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

10-6. 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:

RemCmd: 1023 Off DIAG1

OutI1: 0 A
OutI2: 0 A
IsrcFb: 0 A

RemCmd − This is the value of the remote command and the status of the remote contactor.
Out I1 − This is the value of the tank current.
Out I2 − Not Used.
Isrc FB − This is the value of the amperage in the current source inverter.

kW
The second diagnostic screen is available by again pressing and holding the Run Status button and pressing the Parameters V
A button.
Hz

VLnA−B: 460V Therm1: 77 DIAG2

VLnB−C: 460V Therm2: 77 Therm5: OPEN
VLnC−A: 460V Therm3: 77
VBus: 650V Therm4: OPEN ExtInt: Off

OM-229 158 Page 37

VLnA-B − This is the approximate phase to phase line voltage between phases A and B.

VLnB-C − This is the approximate phase to phase line voltage between phases B and C.

VLnC-A − This is the approximate 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).

ExtInt − This is the status of the relay contacts for a remote protection device..

S OFF

S ON

kW
The third diagnostic screen is available by again pressing and holding the Run Status button and pressing the Parameters V
A button.
Hz

This screen displays the values of cycles and running time. Cycle Counts and Run−Time can be reset to zero (0). Lifetime Cycles and Lifetime Run−
Time values cannot be reset.

Cycle Counts.....: 0 CYCLES

Lifetime Cycles..: 0
Run−Time.........: 0d 0h 0m 0.0s
Lifetime Run−Time: 0d 0h 0m 0.0s

Press the Increase or Decrease button simultaneously to reset Cycle Counts and Run−Time.

Press Program
to reset cycle counts

Press the Program button and the cycle counts and run time will be reset to zero (o).

OM-229 158 Page 38

10-7. Removing Wrapper and Measuring Input Capacitor Voltage
! 900 Volts dc can be present
on the capacitor bus and
significant DC voltage can
remain on capacitors after
Tools Needed: unit is Off. Always check the
voltage on inverter assembly
as shown to be sure the input
5/16, 3/8 in
capacitors have discharged
before working on unit.
! Turn Off welding power
source, and disconnect
input power.
! Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
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

1 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
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

804 600-B

OM-229 158 Page 39

10-8. 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.

804 601-B

OM-229 158 Page 40

Notes

OM-229 158 Page 41

 SECTION 11 − ELECTRICAL DIAGRAM

Figure 11-1. Circuit Diagram

OM-229 158 Page 42

 219 029-B

OM-229 158 Page 43

 SECTION 12 − PARTS LIST
5
3 . Hardware is common and
not available unless listed.
4

See Figure
12-3

12
10
9

7
11
6

See Figure
12-2

11
2
804 601-C
Figure 12-1. Wrappers
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Wrappers

. . . 1 . . . . . . . . . . . . +217 470 .. PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 217 860 .. LABEL, warning electric shock and input pwr (FR) . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . +217 325 .. COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 147 876 .. LABEL, warning general precautionary induction heat . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 217 334 .. PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 217 468 .. DOOR, primary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 168 343 .. HINGE, cont polyolefin copolymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 222 106 .. BRACKET, mtg fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . FM3 . . . . . 236 263 .. FAN, muffin 24VDC 3000 RPM 130 CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 206 270 .. INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 127 836 .. PLUG, tw lk insul male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC2 . . . . . 135 635 .. HOUSING PLUG+PINS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . . . . 131 054 .. HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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-229 158 Page 44

 . Hardware is common and 11
1
not available unless listed.
12

4 5
3

9
10

Ref. 804 602-B

Figure 12-2. Front Panel
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-2. Front Panel

. . . 1 . . . . . . . . . . . . . 217 323 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ........................ NAMEPLATE (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 216 224 . . PANEL, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . PC10 . . . . 239 271 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . PC2 . . . . . 229 148 . . CIRCUIT CARD ASSY, operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . S1 . . . . . 244 920 . . SWITCH, tgl 3pst 40A 600VAC SCR Term Wide TGL . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 252 731 . . LABEL, warning read labels on/off storage temp . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 115 440 . . STANDOFF, no 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . 10 . . . . . . . . . . . . . 224 143 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 228 168 . . PLATE, TC receptacle blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 203 310 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG24 . . . . 115 091 . . HOUSING PLUG+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . CT1 . . . . . 220 821 . . XFMR, current primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . CT3 . . . . . 220 822 . . XFMR, current bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . CT4 . . . . . 220 823 . . XFMR, current output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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-229 158 Page 45

 1
. Hardware is common and 2
not available unless listed. 3 4
20

19
5
16
15
18
17
14

13

12
6

11 10 Figure 12-3. Rear Panel 804 603-A

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-3. Rear Panel

. . . 1 . . . . . . . . . . . . . 217 324 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 224 042 .. CONNECTOR, circ CPC protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 170 391 .. CONNECTOR, circ MS protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 220 824 .. COVER, receptacle weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 147 195 .. NUT, 375−27 .54 hex .25 H nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 127 837 .. RECEPTACLE, tw lk insul fem (dinse type) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 196 247 .. ENDPLATE, output enclosure bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 192 515 .. BRACKET, mtg output block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 228 169 .. PANEL, rear output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 186 523 .. STRIP, mtg output assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 218 693 .. ASSY, output plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . 229 153 .. INSULATOR, output TOCCOTRON AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 196 245 .. ENCLOSURE, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . +196 246 .. ENDPLATE, output enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 602 498 .. LABEL, danger high voltage 2 1/4 x 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . CB1 . . . . . 089 807 .. SUPPLEMENTARY PROTECTOR, man reset 1P 2.5 A 250 VAC . . . . . . 1
. . . 18 . . . RC1 . . . . . 252 561 .. RECEPTACLE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . RC14 . . . . 143 976 .. RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . RC13 . . . . 047 637 .. HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC13 . . . . 079 739 .. CONN, circ cpc clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 047 636 .. SERVICE KIT (RC13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141 162 .. SERVICE KIT (RC14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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-229 158 Page 46
 . Hardware is common and 14
not available unless listed.
1

14
12

6
2
5

10

13
7
3

6
9 16
15
8

804 221-D
Figure 12-4. Base w/Components
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-4. Base w/Components

. . . 1 . . . . . . . . . . . . . 217 328 .. FRAME, lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 213 865 .. BASE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 213 939 .. LABEL, warning electric shock can kill significant . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . L1,L2 . . . . 218 692 .. INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . 216 815 .. BRACKET, cap support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . C1,2 . . . . 213 870 .. CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . T1 . . . . . 213 583 .. TRANSFORMER, hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . T1 . . . . . 227 065 .. TRANSFORMER, hf (400V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 216 629 .. BRACKET, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . FM1,FM2 . . 222 728 .. FAN, nuffin 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . RC4 . . . . . . 115 090 .. HOUSING PLUG+PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 217 992 .. BAFFLE, air bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 224 973 .. INSULATOR, lift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 603 115 .. WEATHERSTRIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . 026 627 .. GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4 . . . . . 115 094 .. HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 226 837 .. WASHER, rubber .343 id x .875 od x .093 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . 226 838 .. INSULATOR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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-229 158 Page 47

 . Hardware is common and 13
14
not available unless listed.

7
13

10
1

9
4

3
5

11
12

804 604-B
Figure 12-5. Top Windtunnel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-5. Top Windtunnel

. . . 1 . . . . . . . . . . . . . 218 424 .. WINDTUNNEL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 218 684 .. HEAT SINK, AC commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 025 248 .. STANDOFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . RT2 . . . . . 222 327 .. THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 605 339 .. WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 250 975 .. INSULATOR, tank cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . PC5 . . . . . 239 257 .. KIT, circuit card assy intrcnct bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 208 591 .. SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . . 12
. . . 10 . . . . . . . . . . . . . 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 11 . . . . F1 . . . . . 225 514 .. FUSE, crtg 2. amp 600 V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 225 553 .. HOLDER, fuse crtg 30 A 600 V 13/32 X 1−1/2 LG . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 229 509 .. EXTENSION, adapter tank capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG32 . . . . 115 091 .. HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG51,57 . . . 115 093 .. HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG58 . . . . 115 094 .. HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 227 082 .. CHOKE, common mode (400 V model only) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 251 158 .. Cap Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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-229 158 Page 48
 18
. Hardware is common and 1
not available unless listed.

17

6
5
4

15

16

13
8 3
10 9

11 14 12
804 605-C

Figure 12-6. Right Windtunnel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-6. Right Windtunnel

... 1 ............. 253 366 .. WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ............. 213 873 .. HEAT SINK, current source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ............. 213 871 .. GROMMET, rbr sil 3.000 ID x 3.250 mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 ............. 170 647 .. BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
... 5 ............. 223 120 .. BLOCK, term 115 amp 3 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............. 148 743 .. LUG, univ w/scr 600V 2−14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . RT1 . . . . . 222 326 .. THERMISTOR, ntc 30 k ohm at 25 deg C 34 in lead . . . . . . . . . . . . . . . . . 1
... 8 ............. 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
... 9 ............. 224 391 .. PANEL, insulating mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 ............. 605 339 .. WASHER, TOOTH .377 ID X 0.507 OD X .022T stl pld . . . . . . . . . . . . . . . 2
... 11 . . . PC4 . . . . . 239 240 .. KIT, circuit card assy intrcnct I srce inpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 ............. 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 ............. 176 879 .. SCREW, M5 − .8 x 12 hex hd−phl 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
... 14 . . . PC8 . . . . . 239 275 .. CIRCUIT CARD ASSY, bus intrcnct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 ............. 208 591 .. SCREW, M 5− .8X 12 soc hd−torx stl pld sems . . . . . . . . . . . . . . . . . . . . . . 14
OM-229 158 Page 49
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-6. Right Windtunnel (Continued)

. . . 16 . . . . . . . . . . . . . 229 728 . . STRAP, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 17 . . . . . . . . . . . . . 030 170 . . BUSHING, snap−in nyl .750 id x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 245 842 . . ASSY, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG64,410,
411 . . . . . . 115 093 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . PLG47 . . . . 115 091 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG45,61 . . 131 204 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . PLG111, 112
121, 132,
141, 142 . . . 131 054 . . HOUSING RCPT+SKTS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*Recommended Spare Parts.
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-229 158 Page 50

 . Hardware is common and 12
not available unless listed. 1

10

2
8
6
13

14

3 15
5

11
9
804 225-A

Figure 12-7. Left Windtunnel

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-7. Left Windtunnel

... 1 . . . . . . . . . . . . . 216 631 .. WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . 218 683 .. HEAT SINK, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . 170 647 .. BUSHING, snap-in nyl 1.312 ID x 1.500 mtg hole . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . 025 248 .. STAND-OFF, insul .250−20 x 1.250 lg x .437 thd . . . . . . . . . . . . . . . . . . . . 8
... 5 . . . . . . . . . . . . . . 115 443 .. STAND-OFF, no 6−32 x .750 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
... 6 . . . . . . . . . . . . . 083 147 .. GROMMET, scr no 8/10 panel hole .312 sq .500 high . . . . . . . . . . . . . . . . 2
... 7 . . . RT3 . . . . . 222 327 .. THERMISTOR, ntc 30 k ohm at 25 deg C 24 in lead . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . 030 170 .. BUSHING, snap-in nyl .750 ID x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 218 430 .. COVER, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 220 825 .. BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . C7-C10 . . . 218 687 .. CAPACITOR, polyp film 1.35 uf 700 VAC +5% −0% . . . . . . . . . . . . . . . . . . 4
... 11 . C7-C10 . . . 225 775 .. CAPACITOR, polyp film 1.10 uf 700 vac +5% −0% (400 V model only) 4
... 12 . . . . T2 . . . . . 219 002 .. TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . PC7 . . . . . 239 266 .. KIT, circuit card assy intrcnct I srce out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . PC1 . . . . . 239 708 .. CIRCUIT CARD ASSY, ps control w/program . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 212 038 .. SCREW, M4 − .7 x 8.5 pan hd−phl stl pld slffmg . . . . . . . . . . . . . . . . . . . . . 8

OM-229 158 Page 51

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-7. Left Windtunnel (Continued)

. . . . . . . PLG16,
121,122 . . . 131 054 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . PLG19,
120 . . . . . . 115 094 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG15,
118 . . . . . . 115 093 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG77,
119 . . . . . . 115 092 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG17 . . . . 115 091 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG18,
116 . . . . . 131 056 . . HOUSING RCPT+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG13,
113 . . . . . 162 382 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG14 . . . 130 203 . . HOUSING PLUG+SKTS,(SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
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-229 158 Page 52

Notes
Notes

TM-216 869 Page 54 Dynasty 350/700, Maxstar 350/700

 Warranty
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
This limited warranty supersedes all previous manufacturers 5. 6 Months — Parts
warranties and is exclusive with no other guarantees or * Batteries
warranties expressed or implied. * Bernard Guns (No Labor)
LIMITED WARRANTY − Subject to the terms and conditions * Tregaskiss Guns (No Labor)
below, warrants to its original retail purchaser that new 6. 90 Days — Parts
equipment sold after the effective date of this limited warranty is * Accessory (Kits)
free of defects in material and workmanship at the time it is
* Canvas Covers
shipped from factory. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR * Induction Heating Coils and Blankets, Cables, and
IMPLIED, INCLUDING THE WARRANTIES OF Non-Electronic Controls
MERCHANTABILITY AND FITNESS. * M-Guns
* MIG Guns and Subarc (SAW) Guns
Within the warranty periods listed below, manufacturer will
repair or replace any warranted parts or components that fail * Remote Controls and RFCS-RJ45
due to such defects in material or workmanship. Manufacturer * Replacement Parts (No labor)
must be notified in writing within thirty (30) days of such defect or * Roughneck Guns
failure, at which time manufacturer will provide instructions on * Spoolmate Spoolguns
the warranty claim procedures to be followed. Limited Warranty shall not apply to:
Manufacturer shall honor warranty claims on warranted 1. Consumable components; such as contact tips,
equipment listed below in the event of such a failure within the cutting nozzles, contactors, brushes, relays, work
warranty time periods. All warranty time periods start on the station table tops and welding curtains, or parts
delivery date of the equipment to the original end-user that fail due to normal wear. (Exception: brushes
purchaser, and not to exceed one year after the equipment is and relays are covered on all engine-driven
shipped to the distributor. products.)
1. 5 Years Parts — 3 Years Labor 2. Items furnished by manufacturer, but manufactured by
* Original Main Power Rectifiers Only to Include others, such as engines or trade accessories. These
SCRs, Diodes, and Discrete Rectifier Modules items are covered by the manufacturer’s warranty, if
2. 3 Years — Parts and Labor any.
* Auto-Darkening Helmet Lenses (Except Classic 3. Equipment that has been modified by any party other
Series) (No Labor) than manufacturer, or equipment that has been
* Engine Driven Welding Generators improperly installed, improperly operated or misused
(NOTE: Engines are Warranted Separately by based upon industry standards, or equipment which
the Engine Manufacturer.) has not had reasonable and necessary maintenance,
* Inverter Power Sources (Unless Otherwise Stated) or equipment which has been used for operation
* Oxy-Fuel Cutting Torches (No Labor) outside of the specifications for the equipment.
* Plasma Arc Cutting Power Sources MANUFACTURER’S PRODUCTS ARE INTENDED FOR
* Process Controllers PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL
* Semi-Automatic and Automatic Wire Feeders USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
* Smith Series 30 Flowgauge, Flowmeter, and
Pressure Regulators (No Labor) In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at manufacturer’s option: (1)
* Water Coolant Systems (Integrated) repair; or (2) replacement; or, where authorized in writing by
manufacturer in appropriate cases, (3) the reasonable cost of
3. 2 Years — Parts and Labor repair or replacement at an authorized service station; or (4)
* Auto-Darkening Helmet Lenses − Classic Series payment of or credit for the purchase price (less reasonable
Only (No Labor) depreciation based upon actual use) upon return of the goods at
* Fume Extractors − Filtair 400 and Industrial customer’s risk and expense. Manufacturer’s option of repair or
Collector Series replacement will be F.O.B., Factory at Appleton, Wisconsin, or
4. 1 Year — Parts and Labor Unless Specified F.O.B. at an authorized service facility as determined by
manufacturer. Therefore no compensation or reimbursement
* Automatic Motion Devices
for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor)
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 MANUFACTURER BE
(NOTE: Field options are covered for the remaining LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
or for a minimum of one year — whichever is PROFIT), WHETHER BASED ON CONTRACT, TORT OR
greater.) ANY OTHER LEGAL THEORY.
* Flowgauge and Flowmeter Regulators (No Labor) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* RFCS Foot Controls (Except RFCS-RJ45) ANY IMPLIED WARRANTY, GUARANTY OR
* Fume Extractors − Filtair 130, MWX and SWX REPRESENTATION AS TO PERFORMANCE, AND ANY
Series REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* HF Units OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* ICE/XT Plasma Cutting Torches (No Labor)
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
* Induction Heating Power Sources, Coolers INCLUDING ANY IMPLIED WARRANTY OF
(NOTE: Digital Recorders are Warranted MERCHANTABILITY OR FITNESS FOR PARTICULAR
Separately by the Manufacturer.) PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MANUFACTURER IS EXCLUDED AND
* Motor Driven Guns (except Spoolmate Spoolguns) DISCLAIMED BY MANUFACTURER.
* PAPR Blower Unit (No Labor) Some states in the U.S.A. do not allow limitations of how long an
* Positioners and Controllers implied warranty lasts, or the exclusion of incidental, indirect,
* Racks special or consequential damages, so the above limitation or
* Running Gear/Trailers exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
* Spot Welders
from state to state.
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
* Weldcraft-Branded TIG Torches (No Labor) and to the extent that they may not be waived, the limitations and
* Wireless Remote Foot/Hand Controls and exclusions set out above may not apply. This Limited Warranty
Receivers provides specific legal rights, and other rights may be available,
* Work Stations/Weld Tables (No Labor) but may vary from province to province. brand_warr 2013−01
 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

Resources Available
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
Replacement Parts
Owner’s Manuals
Circuit Diagrams

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 2013−01