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Manual Miller Electric Intellifire 250

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  • Miller Electric Intellifire 250 - page 1

    Intellifire 250 Processes Description Induction Heating Power Source Induction Heating OM-184 227K 2006 − 05 V isit our website at www.MillerWelds.com File: Induction Heating ...

  • Miller Electric Intellifire 250 - page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...

  • Miller Electric Intellifire 250 - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Induction Heating Hazards 1 . . . . . . . . ...

  • Miller Electric Intellifire 250 - page 4

    ...

  • Miller Electric Intellifire 250 - page 5

    OM-184 227 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage safety_ihom 5/05 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special s ...

  • Miller Electric Intellifire 250 - page 6

    OM-184 227 Page 2 FIRE OR EXPLOSION hazard. D Do not overheat parts and adhesive. D W atch for fire; keep extinguisher nearby . D Keep flammables away from work area. D Do not locate unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not operate unit in explosive atmosphere. INDUCTION HE A TING can cause burns ...

  • Miller Electric Intellifire 250 - page 7

    OM-184 227 Page 3 1-6. EMF Information Considerations About Induction Heating And The Effects Of Low Fre- quency Electric And Magnetic Fields Th e following is a quotation from the General Conclusions Section of the U.S. Congress, Office of T echnology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields − Background P ...

  • Miller Electric Intellifire 250 - page 8

    OM-184 227 Page 4 SECTION 2 − MESURES DE SECURITE POUR LE CHAUFF AGE P AR INDUCTION ihom_fre 8/03 PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRA VES, VOIRE MORTELLES. TENIR LES ENF ANTS A DIST ANCE. LES PORTEURS D’UN STIMULA TEUR CARDIAQUE DOIVENT PREALABLEMENT CONSUL TER LEUR MEDECIN. Pendant les opérations de chauf ...

  • Miller Electric Intellifire 250 - page 9

    OM-184 227 Page 5 DES FUMEES ET DES GAZ peuvent être dangereux pour votre santé. Le chauf fage à induction génère des fumées et des gaz. Leur inhalation peut être dangereuse pour votre santé. 1. Eloigner la tête des fumées. Ne pas respirer les fumées. 2. A l’interieur , ventiler la zone et/ou utiliser un extracteur pour l’évacuation ...

  • Miller Electric Intellifire 250 - page 10

    OM-184 227 Page 6 2-2. Informations concernant les champs électro-magnétiques (Information EMF) Considérations relatives au chauffage à induction et aux ef fets des champs électriques et magnétiques basse fréquence. Le texte suivant est extrait des conclusions générales Département du Congrès U.S., Office of T echnology Assessment, Effet ...

  • Miller Electric Intellifire 250 - page 11

    OM-184 227 Page 7 SECTION 3 − INST ALLA TION 3-1. Specifications Output Frequency Rated Output Required Reflective Inductance Amperes Input at Rated Load Output 50 or 60 Hz, Three-Phase Overall Dimensions W eight Frequency I n d uc t ance 460 V KV A KW 10 T o 50 kHz 25 kW At 100% Duty Cycle − Max 750 A (RMS), 700 V (RMS) 2.5 T o 50 μ h 39 0.29 ...

  • Miller Electric Intellifire 250 - page 12

    OM-184 227 Page 8 sb7.1* 3/93 - Ref. S-0004-A / Ref. S-0750 / Ref. ST -801 826-C 3-3. Remote 14 Receptacle RC14 Information and Connections 1 Front Panel 2 Plug 3 Threaded Collar 4 Keyway 5 Remote 14 Receptacle RC14 (See Section 3-4) T o connect to receptacle, align key- way , insert plug, and tighten threaded collar . 2 3 AJ B K I C L NH D M G E F ...

  • Miller Electric Intellifire 250 - page 13

    OM-184 227 Page 9 3-5. Connecting 3-Phase Input Power For Models With Customer Supplied Cord 803 766-A / Ref. ST-801 825-C 5/16 in 3/8 in T ools Needed: Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors fro ...

  • Miller Electric Intellifire 250 - page 14

    OM-184 227 Page 10 3-6. Electrical Service Guide 60 Hz Three Phase Input V oltage 460 Input Amperes At Rated Output 39 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 45 Normal Operating 3 60 Min Input Conductor Size In A WG 4 8 Max Recommended Input Conductor Length In Feet (Meters) 287 (87) Min Grounding Conductor Size In A WG 4 10 ...

  • Miller Electric Intellifire 250 - page 15

    OM-184 227 Page 1 1 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Clean and tighten output connections. Repair or replace cracked cables and cords. 6 Months Replace damaged or unreadable labels. Blow out or vacuum inside. 5-2. ...

  • Miller Electric Intellifire 250 - page 16

    OM-184 227 Page 12 Ref. ST-801 826-A T ools Needed: 5-5. Measuring T uning Capacitor V oltage Y Significant AC voltage can remain on capacitors after unit is Off. Always check ALL capacitors as shown to be sure they have discharged before working on unit. 3/8 in T urn Of f power source and disconnect input power . Remove wrapper . 1 Tuning Capacito ...

  • Miller Electric Intellifire 250 - page 17

    OM-184 227 Page 13 Ref. ST-801 826-C / Ref. 801 828-C 5-6. Ground Fault Protection Ground fault protection circuitry automatically shuts down the power source output if a potentially hazardous condition exists at the heating device connected to the power source (e.g. insulation has broken down on a heating blanket causing the conductor to come into ...

  • Miller Electric Intellifire 250 - page 18

    OM-184 227 Page 14 Ref. ST-801 826-A T ools Needed: 5-7. Measuring Input Capacitor V oltage 3/8 in Y Significant DC voltage can remain on capacitors after unit is Off. Always check ALL capacitors as shown to be sure they have discharged before working on unit. T urn Of f power source and disconnect input power . Remove wrapper . 1 Input Capacitor C ...

  • Miller Electric Intellifire 250 - page 19

    OM-184 227 Page 15 5-8. Diagnostic LED’ s Ref. ST-801 826-B 1 Diagnostic LED’s Use diagnostic LED’ s to determine operating condition of power source. 2 Current Source Limit: 1 10 A Fault: 1 15 A 3 Over Frequency Limit: 50 kHz Fault: 55 kHz 4 Under Frequency Limit: 10 kHz Fault: 5 kHz 5 Current Reactive Limit: 700 A 6 T ank V oltage Limit: 67 ...

  • Miller Electric Intellifire 250 - page 20

    OM-184 227 Page 16 5-9. T roubleshooting T rouble Remedy No heat output. Replace building line fuse or reset circuit breaker . Secure head/coil connecting plate to power source connecting block (see Section 3-2). Check and replace Power switch if necessary . Connect power source to proper input voltage or check for low line voltage. No heat output; ...

  • Miller Electric Intellifire 250 - page 21

    OM-184 227 Page 17 Notes ...

  • Miller Electric Intellifire 250 - page 22

    OM-184 227 Page 18 SECTION 6 − ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram ...

  • Miller Electric Intellifire 250 - page 23

    OM-184 227 Page 19 204 963-A ...

  • Miller Electric Intellifire 250 - page 24

    OM-184 227 Page 20 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. Figure 7-1. Main Assembly 801 828-F 1 Fig. 7-2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 27 38 39 40 12 33 31 32 30 34 35 36 37 28 42 41 26 29 ...

  • Miller Electric Intellifire 250 - page 25

    OM-184 227 Page 21 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly 1 179 245 P ANEL, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Figure 7-2 CENTER BAFFLE ASSEMBL Y 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Intellifire 250 - page 26

    OM-184 227 Page 22 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Center Baffle Assembly (Fig 6-1 Item 2) 1 PM1,2 223 949 KIT , transistor IGBT module 75A 1200V 94 X 35.6MM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . PLG21,22 1 15 094 HOUSING PLUG & SKTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Intellifire 250 - page 27

    OM-184 227 Page 23 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Center Baffle Assembly (Fig 6-1 Item 2)(Continued) 9 179 233 WINDTUNNEL LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 L1 180 1 14 INDUCTOR, input 1 . . . . . . . . . . . . . . . ...

  • Miller Electric Intellifire 250 - page 28

    Notes ...

  • Miller Electric Intellifire 250 - page 29

    Notes ...

  • Miller Electric Intellifire 250 - page 30

    Notes ...

  • Miller Electric Intellifire 250 - page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric Intellifire 250 - page 32

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte rs − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F AX: 920-735-4125 European Headqua rters − ...

Manufacturer Miller Electric Category Welding System

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric Intellifire 250 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric Intellifire 250.

A complete Miller Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Miller Electric Intellifire 250 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Miller Electric Intellifire 250, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Miller Electric Intellifire 250, that we can find in the current document
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