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Miller Electric ProHeat 35 User's Manual

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1. Single Air Cooled Output Connection Output Connector 1 Output Connector 2 Protective Plug Air Cooled Extension Cable OND 5 Liquid Cooled Extension Cable The power source is capable of single or dual output When connected for single power output up to 35 kW is available at the single output connection When connected for dual power output power is divided between the two output Single Liquid Cooled Output Connection connections Single Air Cooled Output Connection Connect air cooled output extension cable to Output Connector 1 or Output Connector 2 Connect Protective Plug to remaining Output Connector Single Liquid Cooled Output Connection Connect liquid cooled output extension cable to Output Connector 1 or Output Connector 2 Connect Protective Plug to remaining Output Connector Dual Air Cooled Output Connection Dual Liquid Cooled Output Connection Ref 803 993 C Ref 804 217 A Dual Air Cooled Output Connection C
2. gs For temperature control mode the power source must have as a minimum one thermocouple connected to receptacle TC1 If multiple thermocouples are desired either use individual thermocouple plugs or the thermocouple extension cable To connect thermocouples to the power source proceed as follows EF Do NOT weld thermocouples to work piece while thermocouple cable is con nected to the power source Turn Off power source 1 Power Source 2 Thermocouple Receptacles 3 Individual Thermocouple Extension Cable 4 Multiple Thermocouple Extension Cable Align plug pin s with receptacle socket s and push plug into receptacle 804 320 A OM 222 166 Page 20 4 15 Attaching Welded Thermocouples Do NOT weld thermocouples while connected to power source 1 Attach thermocouples using a portable Thermocouple Attachment Unit TAU This unit spot welds thermocouple wire directly to the workpiece This method of thermocouple attachment ensures accurate temperature measurement Clean file or grind any loose scale or rust from the workpiece at the places where the wires will be attached Clean the location for the lead magnet to minimize resistance Place the magnet as near to the thermocouple positions as possible Strip 1 4 inch of insulation from the thermocouple wires Set the output variable control of the TAU to about eighty percent 80 o ot WN
3. GND PE Earth Ground A Installation must meet all National and Local Codes have only qualified per sons make this installation A Disconnect and lockout tagout input power before connecting input con ductors from unit A Make input power connections to the welding power source first A Always connect green or green yellow conductor to supply grounding termi nal first and never to a line terminal EF The circuitry in this unit automatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to either 400 or 460 VAC input 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 4 4 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Con nections 2 Strain Relief Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow
4. OM 222 166K 2007 11 m Processes Miller Induction Heating Description EJ LG Induction Heating Power Source ce ProHeat 35 OWNER S MANUAL Visit our website at File Induction Heating www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U E Bl E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do s every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for some reason
5. e Wearers of Pacemakers and other Implanted Medical Devices should keep away from serv icing areas until consulting their doctor and the device manufacturer 2 I OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle D e Reduce current or reduce duty cycle before us D ing induction heating equipment again e Do not block or filter airflow to unit 8 3 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 8 4 EMF Information Considerations About Induction Heating And The Effects Of Low Fre quency Electric And Magnetic Fields Induction heating current as it flows through induction heating cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric
6. Grasp one of the stripped wires with the tip of the jaws of the application pliers EF Don t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit This will cause the thermocouple wire to fuse to the pliers rather than the workpiece 7 Press the end of the wire to the workpiece at ninety degrees to the surface and maintain a firm pressure Make sure the Thermocouple Attach ment Unit is charged and wait for the ready light to glow Press discharge button and the wire should weld to the workpiece There will be a sharp crack and a slight arc flash Repeat the process with the other wire placing it approximately 1 4 inch away from the first wire Attach a spare thermocouple and support both thermocouples approximately 18 inches back from the connection with a band or fiber tape 10 Carefully bend the wire over at right angles This brings the thermocouple wires out along or parallel to the workpiece It also tests the strength of the weld If the weld shows signs of breaking remove the wire restrip the end and repeat the process Strap Or Tape Thermocouple Wires lt A A 804 322 A OM 222 166 Page 21 4 16 Using Contact Thermocouples The welded thermocouples discussed previously can be used for preheating or stress relieving As an alternative in preheating applications a contact temperature sensor can be used This eliminates the need to weld t
7. oke Ke oeeo i Aa Aa t o O I Ee I BX LZ H Es i i zZ FF Z 5 y A AE gt When a control panel button is pushed the yellow lamp lights to indicate ac tivation 1 Power Switch Use switch to turn power source On and Off 2 TC1 4 Temperature Display Provides temperature display of thermo couples 1 through 4 3 Control Thermocouple LED s LED s indicate which thermocouples 1 4 are used to control the heating process 4 Temperature Units LED s LED s indicate units for temperature mea surements F or C 5 Fault LED LED lights to indicate a system fault condi tion 6 Limit LED LED lights to indicate a system limit condi tion 7 Heat On LED LED lights to indicate the power source out put is energized 8 Stop Button Use button to stop a heating process 9 Hold Button Use button to hold a heating process 10 Run Button Use button to run a heating process 11 Cursor Button Use button to move selection cursor in the 4 x 40 LCD display item 18 12 Program Button Use button to program the process control 13 Run Status Button Use button to display real time operating status 803 995 B 14 Parameter Button Use button to display real time power source operating parameters 15 Cooler Button Use button to turn cooler On and Off 16 Increase Button Use button to increase values in set up screen 17 Decrease Button Use button to decrease value in program sc
8. 8 1 Symbol Usage DANGER Indicates a hazardous situation which if 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 plained in the text NOTICE Indicates statements not related to personal injury 8 2 Servicing Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard A Only qualified persons should service test maintain and re pair this unit A During servicing keep everybody especially children away e ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off induction heating power source and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from recep tacle or stop engine before servicing unless the procedure specifi cally requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e Do not leave live unit unattended e If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the jo
9. BUSHING snap in nyl 750 id x 1 000 mtg hole 1 EE 231 050 i SASSY resIStOl eege ae bie e 1 EN PLG64 410 411 115 093 HOUSING PLUG SKTS SERVICE KIT 3 AN PAS DEU PLG47 115 091 HOUSING PLUG SKTS SERVICE KIT 1 STENT PLG45 61 131204 HOUSING PLUG SKTS SERVICE KIT 2 Dr uns PLG62 201 665 HOUSING PLUG SKTS SERVICE KIT d BA PLG63 115 094 HOUSING PLUG SKTS SERVICE KIT 1 iE sata PLG111 112 121 132 141 142 181054 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 222 166 Page 59 F Hardware is common and not available unless listed 11 9 804 225 A Figure 11 9 Left Windtunnel Item Dia Par No Mkgs No Description Quantity Figure 11 9 Left Windtunnel T WEE 216631 WINDTUNNEL DH 1 Nc 218 683 HEAT SINK diode 1 DE uc re 170 647 BUSHING snap in nyl 1 312 ID x 1 500 mtg hole 2 NR MH TEASE 025 248 STAND OFF insul 250 20 x 1 250 lg x 437 thd
10. KANAN e 803 993 C 4 14 Locating Thermocouples P2 Thermocouple location is one of the most critical steps in the Heat Treatment Operation Thermocouples shall be located as follows to provide a survey of heating uniformly and enable time and temperature control de Locate thermocouples to ensure that the full area of the heat band is monitored The code normally specifies the number of thermocouples to be used based on the pipe diameter The control thermocouple is placed in the plane of the weld center of the heat zone The control thermocouple is placed at the top of the pipe in a standard pipe joint configuration In other applications the thermocouple should be located in the hottest portion of the weldment to be stress relieved 2 Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due to heat convection or conduction and have additional thermocouples applied Attach a spare thermocouple beside control thermocouples Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces Physically inspect all thermocouples for continuity and mark them by an identification number corresponding to the recorder channel D Dm kh Match the drawings of the workpiece indicating the numerous thermocouple locations controlling thermocouple locations etc to weld ident
11. Service required F60 Temperature Sensor Fault Check control TC connections Check control TC extension cable F61 Coolant Flow Fault Check for coolant leak Clean for coolant blockage Check coolant filter and level Check coolant connections 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 OM 222 166 Page 43 Fault Condition Additional Information F67 Over Frequency Fault Verify heating cable properly wrapped Verify material being heated is magnetic F68 Cable Connection Fault Check for loose open output connection Verify all output cables are same type Verify receptacle plug connected F69 Coolant Overtemp Fault Check coolant flow and level Increase number of turns Verify appropriate insulation thickness Clean coolant filters and heat exchanger F70 Internal Communication Fault Service required F71 Internal Thermistor Fault Service required F72 Coolant Thermistor Fault Service required F73 Decoupled Open Coil Service required F74 Isolation Fault Self Test Error Service required
12. teur de mise la terre appropri et rev rifier les connexions A L installation l utilisation l entretien et les r parations ne e Les cables doivent tre exempts d humidit d huile et de graisse doivent tre confi s qu des personnes qualifi es prot gez les contre les tincelles et les pi ces m talliques chau A des Au cours de l utilisation tenir toute personne l cart et plus e V rifier fr quemment le cordon d alimentation afin de s assurer qu il particulierementles enfants n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort UNE D CHARGE LECTRIQUE peut e L quipement doit tre hors tension lorsqu il n est pas utilis m e T TH n P H 1 N entra ner la mort e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Le contact de composants lectriques peut provo e Ne pas enrouler les c bles autour du corps quer des accidents mortels ou des br lures graves E DS e Le circuit lectrique et les barres collectrices ou les e Ne pas toucher le circuit lectrique si l on est en contact avec la pi connexions de sortie sont sous tension lorsque ce la terre ou le circuit lectrique d une autre machine ne Nutier qu un mat rie en bon tat R parer ou remplacer sure sur marche Des quipements install s ou reli s la borne de terre de champ les pi ces endommag es Entretenir l appareil conform mani re
13. 6 4 1 3 PWHT Post Weld Heat Treat The post weld heat treat process allows the operator to program a post weld heat treat where ramp temperature on increase and decrease and ramp rates are the same When this process is selected the following screen appears on the display PWHT Screen Mode PWHT Control TC gt 1 2 Ramp Temp 200 Ramp Rate 600 Hr Soak Temp 400 Soak Time 01 00 00 OM 222 166 Page 27 O O The default position of the cursor is next to Control TC Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1 2 3 or 1 2 3 4 TC1 MUST always be a control thermocouple TC2 thru TC4 can be used for controlling or monitoring When a thermocouple is selected as control the LED adjacent to the seven segment display illuminates Use the Cursor button to move the cursor to the desired selection Ramp Temperature Ramp Rate Soak Temperature or Soak Time and press the Increase AN or Decrease ES button to change the value to the desired setting D KB Soak Temp p Soak TIME Ramp Rate 7 mE Ramp Temp Figure 6 1 Soak Parameters 5 The minimum and maximum ramp temperature settings for PWHT are O and 1450 F 18 and 788 C The minimum and maximum ramp rates are 10 and 9999 F hr 6 and 5555 C hr The minimum and maximum soak temperatures are O and 1450 F 18 and 788 C The
14. S assurer que l air ambiant ne pr sente aucun danger Ne pas chauffer dans des endroits se trouvant proximit d op ra tions de d graissage de nettoyage ou de pulv risation La chaleur peut r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Ne pas surchauffer des m taux munis d un rev tement tels que l acier galvanis plaqu au plomb ou au cadmium moins que le rev tementne soit enlev de la zone chauff e que la zone soit bien ventil e et si n cessaire en portant un respirateur Les rev tements et tous les m taux contenant ces l ments peuvent d gager des fum es toxiques s ils sont surchauff s Voir les informations concernant la temp rature dans les sp cifications de rev tement MSDS y Risque D INCENDIE OU D EXPLO f SION 4 e Ne pas surchauffer les composants e Attention aux risques d incendie tenir un ex tincteur a proximite Stocker des produits inflammables hors de la zone de travail Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables Ne pas installer l appareil proximit de produits inflammables Ne pas faire fonctionner l appareil si l air ambiant est charg de parti cules gaz ou vapeurs inflammables vapeur d essence par exemple e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appro
15. the output is on The input power circuit and machine internal circuits are also live when power is on Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Enclose any connecting bus bars and coolant fittings to prevent unintentional contact Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or ac cidental contact with the workpiece or ground For these conditions see ANSI 249 1 listed in Safety Standards And do not work alone e Disconnect input power before installing or servicing this equip ment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Use only nonconductive coolant hoses with a minimum length of 18 inches 457 mm to provide isolation e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input pow er cord ground wire is proper
16. 090 HOUSING PLUG PINS service KD 0 0 cece eee 1 BT at 217992 BAFFLE air bottom n n 1 D ARA au 224 973 INSULATOR lift frame eee ens 2 ARA 603 115 WEATHERSTRIPPING isat e A ele cece eee KE ATS KIR NS ees 2 ARE EEN 026 627 GASKET lifting eye cover 1 Lie inah PLG4 115 094 HOUSING PLUG SKTS SERVICE KIT 1 a MD C PAA Nag 226 837 WASHER rubber 343 id x 875 odx 093thk 2 NG a Rah TR 226 838 INSULATOR capacitor teen eens 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 222 166 Page 53 IS Hardware is common and not available unless listed Fi aed 1 6 1 804 222 A Figure 11 5 Top Windtunnel Item Dia Part No Mkgs No Description Quantity Figure 11 5 Top Windtunnel sha Dares ia 218 424 WINDTUNNEL mp 1 en PAA Bip katao ant 218 684 HEAT SINK AC commutator 1 shoe Un dvd 025 248 STANDOFF insul 250 20 x 1 250 lg x 437 thd 4 ox Za RTI2 os 222327 THERMISTOR ntc 30 k ohm at 25 deg C 24 inlead 1 MAN lt TR erie 083 147 GROMMET scr no 8 10 panel hole 312 sq 500 high 2
17. 2i Bb joa EA ae eed Gand ee DEES PLG64 410 ATE iu 115093 HOUSING PLUG SKTS SERVICE KIT NIU ua PLG47 115091 HOUSING PLUG SKTS SERVICE KIT CENT PLG45 61 131204 HOUSING PLUG SKTS SERVICE KIT banatan ata PLG62 201665 HOUSING PLUG SKTS SERVICE KIT EH PLG63 115 094 HOUSING PLUG SKTS SERVICE KIT CH PLG111 112 121 132 141 142 131 054 HOUSING RCPT SKTS SERVICE KIT 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 222 166 Page 57 Hardware is common and not available unless listed 804 431 E Figure 11 8 Right Windtunnel 400 V Model Only Item Dia Part No Mkgs No Description Quantity Figure 11 8 Right Windtunnel 400 V Model Only Na EE 216 630 WINDTUNNEL RH pie X 99 ATR 9 T cece hr 1 EA 213 873 HEAT SINK current source eens 1 HE derat EE 213 871 GROMMET rbr sil 8 000 ID x 3 250 mtg hole 2 TE AAAH 170 647 BUSHING snap in nyl 1 312 ID x 1 500 mtg hole 1 dup D uisa se Aa 225 356 CIRCUIT CARD ASSY input filter ooooocccccoccccoooo 1
18. 5 Fault Condition Codes a AE EEE ssh 43 9 6 System Diagnostic Screens 44 9 7 Removing Wrapper and Measuring Input Capacitor Voltage 46 SECTION 10 ELECTRICAL DIAGRAM 0 0 c cece eee eee ERE RER RER RER RENE RER 48 SECTION 14 PARTS LIST enee E oh eta eects xem ei m hd eee ew te RERUM NE NINE CR 50 WARRANTY Declaration of Conformity for European Community CE Products EF This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 dos Declares that this product P ro H e at 35 conforms to the following Directives and Standards European Contact Signature Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility Directives 89 336 EEC 92 31 EEC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirments And Tests IEC 60664 1 Ed 1 1 The product technical file is maintained by t
19. DC EE 115 443 STAND OFF no 6 32 x 750 lg 250 hex 5 RP EE 148 743 LUG univ w scr 600V 2 14 wire 250 stud 1 sano Bats RTT us 222326 THERMISTOR ntc 30 k ohm at 25 deg C 34 in lead 1 Lx Iaa eu ah 083 147 GROMMET scr no 8 10 panel hole 312 sq 500 high 6 out 224391 PANEL insulating mtg capacitor cece eee 1 vi 1 ssa e 605 339 WASHER TOOTH 377 ID X 0 507 OD X 022T stl pld 2 12 PC4 228 407 KIT circuit card assy intrenct srce inpt 1 E KEEN 212 038 SCREW M4 7 x 8 5 pan hd phl stl pld 2 iau dA EE 226 579 SPACER leads iiis iu oed Reciente ac Eneas Ag aA 1 eed CA 176 879 SCREW M5 8x 12 hex hd phl 8 8 pld 12 si 1 lt cans geg rat 226 041 BRACKET mtg ce filter ground plane 1 D RO 216 262 CIRCUIT CARD ASSY cooler control 1 FSR KENE 228 262 CIRCUIT CARD ASSY bus intrenct 1 OM 222 166 Page 58 Item Dia Part No Mkgs No Description Quantity Figure 11 8 Right Windtunnel 400 V Model Only Continued A NA haat 208 591 SCREW M 5 8X 12 soc hd torx stl pld sems 14 See AA 229 728 STRAP connecting 06 c ccc ect nent net O 4 Aon 4 BEA NANG 030 170
20. Decrease NE buttons to select temperature units Selection will D KB drive the F C indicator LED s The factory default is F N Changing from F to C will convert stored program values ramp temperature soak temperature ramp rate and temperature tolerance Tolerance press the Increase or Decrease button to select the desired temperature tolerance 2 KA The factory default is 25 F Backlight press the Increase or Decrease button to turn LCD display backlight On or Off 2 KA The factory default is On Input Type press the Increase or Decrease button to select the desired temperature input 2 KA device N The factory default and only selection is K TC or Decrease Control Mode press the Increase button to select the desired method of system 2 KA control either Temperature or Manual For more details about methods of control see Section 6 4 The factory default is temperature based control or Decrease Power Output press the Increase button to adjust the maximum power source KA output The factory default is 35 kW or Decrease System Lock press the Increase button to lock or unlock the operator interface to 2 KA prevent tampering with any programs Yes indicates the system is locked and No indicates the system is unlocked The factory default is No unlocked IGC All parameters in System Setup are considered global and any changes to the sy
21. Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit 460 575 Se m VOLTS si a a 41 14 5 5 pomeste Lo LINE FILTER olo t RC1 PC12 a q 3 UNITS ONLY Lo BOARD 22 olo 23 RC2 RC1 PLG121 Bog g Lo CE UNITS Ld y LE RC3 400 460 ONLY GRM YEL GG I 5 VOLTS p ARO r lt lt RC1 2 e E 9 CE UNITS ena PC11 PC14 z gz0a y ssl Ce x Lu ONLY ep RC1 PLG111 PCTS RC1 PLG141 E Z ZZ dok R111 RC2 PLG112 RC2 PLG132 RC2 PL6142 Da sussa 94g 361 ESERC1 1 lt RC ket peu RCI CL GE eT TIT 137 E24 RC2 1 NO BARR DI R121 Hg SS EELEE PEG po E Kn MY VON VV RC12 R132 Sep INR BD R AA Hg PEZ IS gt E gt DE COOLER OPTION RARKRA AAA l HDi m NOR orm e FLOW A SCH iilii lid 120 TERE 222 NE 12 3 z la Qc m BIS px DC BUS EE ami GRN YEL zuzz DC BUS RC1 3X Ep pg 2 222 3855 kRC3 5 GND CB1 kRC3 4 TEMP FB spuce ZOO LL res 1 115 v OUT lt RC3 3 FLOW RATE FB
22. E tpm ba eech e 1 EE qu 147 876 LABEL warning general precautionary induction heat 1 to dre d Os ot 21 7334 2 PANEL Side LA 3 Da E ENIM 1 DN EE 217 468 DOOR primary board ees 1 E AA 189 491 SPACER hinge 1 r TENERE 168 343 HINGE cont polyolefin copolymer cece eee eee es 1 5 seine 222 106 BRACKET mig fan 1 10 FM3 236 263 FAN muffin 24VDC 3000 RPM 130 CFM cee eee 1 MAT Banig mere ere 206 270 INSULATOR side PH 2 R 1980355 HANDLE minni ern e a we WE ee eee kms 1 da als 197 931 MAGNET permanent 2 cece eect tenet nee nes 1 b ER 197 900 CABLE work ground 1 KO PR cee 127 836 PLUG tw Ik insul maie nanenane 1 MES RC2 135635 HOUSING PLUG PINS SERVICE KIT d EH PLG2 131054 HOUSING RCPT SKTS SERVICE KIT d bg dati PLG61 131 204 HOUSING PLUG SKTS SERVICE KIT d ts PLG63 115 094 HOUSING PLUG 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 222 166 Page 50 Har
23. 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 9 6 System Diagnostic Screens Additional system diagnostics are available and accessible through the operator interface Detail operational parameters can be accessed by pressing O O and holding the Run Status button and pressing the Parameters EVA button When this feature is initially activated the following screen appears on the LCD display System Diagnostic Screen RemCmd 1023 Off Cablel LOD OutIl 0 A Cable2 LOD OutI2 OA ClntFR 0 75 GPM IsrcFb OA ClrSts Flowing RemCmd This is the value of the remote command and the status of the remote contactor Remote controls can be used to enable disable output They do not affect output power level Out 11 This is the value of the output current on output 1 Out 12 This is the value of the output current on output 2 Isrc FB This is the value of the amperage in the current source inverter Cable 1 This is the cable type hooked up to output number one Possible labels e AIR for an air cooled cable e LQD for a liquid cooled cable e PLUG for a protective plug OPEN no cable or plug in place Cable 2 This is the cable type hooked up to output number two Possible labels e AIR for an air c
24. Interface Indicators 1 2 3 o RENE In o qn o 099 M CG 099 099 o OGN OGN a Ogg A Fee al o I EX E EX i l cl E NY ZZ H a L ee 803 995 B 1 Fault LED 2 Limit LED 3 4x40 LCD Display condition LED lights to indicate a system fault LED lights to indicate a system limit condition Displays programming eters fault and limit troubleshooting guide run status param conditions and OM 222 166 Page 41 9 2 Limit Conditions A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its optimum operating conditions or parameters Should a limit condition occur during operation the yellow Limit LED will flash to indicate a problem If the active screen on the LCD display is Run Status or Parameters a message describing the particular limit condition will appear on the display If the active screen is Program press the O 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 N Acknowledge the limit and continue operation N Terminate operation to correct the problem causing the limit O Pressing the Dec
25. Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Ro LES CHAMPS MAGNETIQUES peuvent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction SUR DA l L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT Ga e Pr voir une p riode de refroidissement MR e R duire le courant de sortie ou le facteur de mar che avant de recommencer le chauffage e Respecter le cycle op ratoire nominal LES CHARGES LECTROSTATIQUES peuvent endommager les circuits im prim s Le e tablir la connexion avec la barrette de terre AVANT de manipuler des cartes ou des pieces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes PC OM 222 166 Page 5 HFJ LE RAYONNEMENT HAUTE FR QUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L util
26. NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org 1 6 EMF Information Considerations About Induction Heating And The Effects Of Low Fre quency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can in teract with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientif ic understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to of Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANS
27. Ras Ree At 32 TABLE OF CONTENTS 6252 RUN Status eg A KANNADA NANA Riven NAINA m p Poi ERA UTERE er eeu E 33 6 5 1 Temperature Based Control ene a hs 33 6 5 1 1 Preheat Bake Out And PWHT Run Status Screen cece eee 33 6 512 Gustom Programs eegen ada hid dant presi prae 33 6 5 2 Manual COhRlrOl char er the rire A ERREUR hee 34 6 6 Parameters aa NANA SE SR as NING EEN 34 6 7 ica vss MEHR EE es REPE NAE dee ELE REGE EEG RN AU dE BUR HN Lue 34 6 8 Real Time Operation E nce pene Bae wee bak REG RS KA NP LANG d age nie ab Gleam guru Es 35 6 9 System Operating Characteristics tenet s 37 SECTION7 MAINTENANCE NENNEN a rana es aaa EIN ie EN ae NNN IN E SINN 38 7 1 Routine Maintenance 48e uses 38 7 2 Blowing Out Inside OURE n siam auaina n 0 38 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING 39 8 1 Symbol Usage es na ND ANAN ede ai maan 39 8 2 Servicing Hazards i ssec ret dE a Ee BUG EE Road CRF eR as 39 8 3 California Proposition 65 Warnings 40 8 4 EME Information cus tati Nana Arsch KPA an de E DEG SR ow eRe nn Dus 40 SECTION 9 DIAGNOSTICS amp TROUBLESHOOTING 41 9 1 Operator Interface Indicators teen een eee eee 41 9 2 Limit COMMONS EE 42 9 3 Limit Condition Codes sehn 42 GE DN A A A RE 43 9
28. a 1 6 1 6 1 6 1 6 1 6 1 6 eee eee leer PE eee jegeg OM 222 166 Page 48 Figure 10 1 Circuit Diagra 3 PC4 RC9 zar NG PC7 RCS La CURRENT SOURCE DIODE INTERCONNECT REAR INTERCONNECT RC7 PLG77 rer LEI RC5 PLG45 ET E E E E SH E ba 56 s Wo GREEN Ges LE Len RC11 PLG4 1 99 zz 998 RED 53 33 o Ek EE 55 EE 25 ES RC4 reng EO Ta max 99 CR ow FRONT E SE Lo RCS RO na Er 8 nos LES 5o 29 5o SO 22 22 CE c c c c c c AN I Mv NN NN NA AA PCB ELIT CAP INTERCONNECT ell Ex Sx S SE 277774 Pr AH SY iu 33 g L3 INSTALLED IN AAAA AAAA A A CE UNITS ONLY N o TON o9 pi oc 2m LI dd dd 5 dd 58 00 OO 60 00 E GRN YEL lt EG nG KE E REAR CAP RC19 8 gt REAR CAP RC19 33 m GAN FRT CAP RC19 65 100 FRT CAP Big m LG2 RC2 RC18 3 gt 232 RC Reg NR O 7 PC5 rh CHU BRIDGE C 5 PLG4 RC4 DIT INTERCONNECT RC1 PLGS 1 RC1B 4 gt ED RCIB 5 5 2 e RC7 PLG57 1 RC18 6 2 1 RCB PLG58 RC20 4 gt lt RC8 4 YELLOW III RC20 3 gt L RC8 3 RC2 L 3 4 NG pC Ess RC20 2 gt e RC8 2 HAM RC20 1 gt k RC8 1 T CONTROL C3 C4 C5 cs RC3 PL613 SHIELDED CABLE 1 1 ISO GND 3 RC13 17 gt gt 24 lt RC1 3 o T SS RT LO GT RC13 7 gt lt RC1 6 po 8 y ISO
29. cause fires Have a fire extinguisher nearby and have a MAON watchperson ready to use it 4 Breathing heating fumes can be hazardous to your health Read Material Safety Data Sheets MSDSs and manufacturers instructions for material used 4 1 Keep your head out of the fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Use ventilating fan to remove fumes 5 Always wear safety glasses or goggles during and around heating operations to prevent possible injury 5 1 Wear either safety glasses or full goggles depending on type of operation and nearby processes 6 Do not remove or paint over cover the label 7 Become trained and read the instructions before working on the machine or heating 190 025 OM 222 166 Page 7 3 2 Warning Label Definitions Continued Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Overuse can cause overheating Follow rated duty cycle Disconnect input plug or power before working on machine Become trained and read the instructions before working on the machine Connect green or green yellow grounding conductor to ground terminal Connect input conductors L1 L2 And L3 to line terminals 194 466 Warning Watch Out There are possible hazards as shown
30. exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep induction heating power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 9 DIAGNOSTICS amp TROUBLESHOOTING The ProHeat 35 power source has on board capabilities to aid in troubleshooting problems should any conditions occur during operation This troubleshooting capability consists of the Fault LED Limit LED and message screens that appear on the front panel LCD display 9 1 Operator
31. grounding conductor to welding power source grounding terminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line terminals Close and secure access door on welding power source Ref 804 430 A Disconnect Device Input Power Connec tions 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding ter minal first 9 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 4 4 fused disconnect switch shown Close and secure door on line disconnect de vice Remove lockout tagout device and place switch in the On position OM 222 166 Page 14 4 7 Power Source Output Connections EZ
32. gt lt RC5 4 115 V RET KRC3 2 GND LRCS 1 5V 467 X GK Te ALU amp RC5 5 115 V RET RC3 PLG3 NGAY ROs 6 WINDING 2 PC6 BLUMWAT e ROS 3 WINDING 1 COOLER POWER SUPPLY RC1 PLG61 455 ZW RC2 PLG62 ELE WHT RC2 1 gt A RED lt lt RCO 1FLOW RATE FB RC2 2 gt BLK XRC9 2TEMP FB RC6 PLG6B EE HAT RC9 3ENABLE RC2 4 gt Sy SHO amp RC9 4GND L RC5 4 BLOWER NEG SHIELDED CABLE GRN YE1 Oy KRC5 8 48V TH 147 1 747 amp RC5 1 PHASE C RED BS 145 JRc5 5 PHASE B BAN Tj 146 amp RC5 6 PHASE A SHIELDED CABLE mh lt RC3 6 THERM HALL B RT1 RC3 16 GND PUMP M1 GND GND amp RC3 7 THERM2 Vec RT2 lt RC3 17 GND pa lt lt RC3 8 THERM RT3 lt lt RC3 18 GND E lt RCS 9 THERM4 Bord RC3 19 GND RC4 1 gt 27 XRC3 1 5 ane RC4 2 SCH 22 LRCIZ 5 PC10 RIBBON CABLE RC4 5 gt 5 KRC3 5 24 DISPLAY RC4 7 gt Eg 27 LRC3 12 GND pa RC4 3 NN SIA LRC3 3 OP INT MOSI PLG RC4 4 DN TS BEN RC3 4 OP INT MISO Rc4 8 gt SHO ke RC3 15 GND Rca g S5 P5 SS RED J Rcs 14 OP INT SS RC4 10 5 P5 SCK CN 1 RC3 15 OP INT SCK SHIELDED CABLE PC2 7 OPERATOR INTERFACE CONDUCTOR RC4 PLG24 RIBBON CABLE ECH PC3 po THERMOCOUPLE INTERFACE RC2 15 7 RC1 PLG31 RC2 2 95 RC2 3 gt RC2 4 S524 RC2 5 6 5 RC2 6 gt E T RC2 7 5 27 RCB PLG38 RC2 8 5 727 RC2 9 gt Nm NN Nm Nm NN NN ddd iii bow AAA iii Add 000 000 ODO DOO DOO 000 c c c c a oc rere rere rere c c c b K LA It It YYY Y YY YYY SYV Y Y Y Y YY R j j j n a a a a a
33. incorrecte sont dangereux ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement Ne pas toucher aux pi ces lectriques sous tension Prot ger toutes les barres collectrices et les raccords de refroidis sement pour viter de les toucher par inadvertance en place e Porter des gants isolants et des v tements de protection secs et Il reste une TENSION DC NON N GLIGEABLE dans sans irous les sources de soudage onduleur quand on a coup e Sisoler de la pi ce couper et du sol en utilisant des housses ou l alimentation des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Avant de toucher des organes internes couper l onduleur i KONER y A d brancher l alimentation et d charger les condensateurs e D autres consignes de s curit sont n cessaires dans les conditions d alimentation conform ment aux instructions indiqu es dans la suivantes risques lectriques dans un environnement humide ou si partie maintenance l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assi se genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions voir ANSI Z49 1 num r dans les normes de s curit En outre ne pa
34. soudage l arc 4 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 5 2 4 Proposition californienne 65 Avertissements 6 2 5 Principales normes de s curit s ne 6 2 6 Information EMF s ilsill ka uu neca em DE amant de Soe ee Dai REGEL 6 SECTIONS S DEFINITIONS Zou e RI de ARN NA ANAL PN NAG DADA BEA EE RE AEL R SEN EEN 7 3 1 Warning Label Definitions ee E an ehe A EEN Io Rud 0 7 3 2 Warning Label Definitions Continued III 8 3 3 Rating Label For CE Products 9 3 4 WEEE Label For Products Sold Within The EU 9 3 5 Symbols And Definitions 10 SECTION 4 INSTALLATION ee rl do 10 4 1 Specifications iege ee eee lak E due RAD P eS ne ND Ne EN ee ER 10 4 2 Selecting A LOCaliOn ore PRA avin e ule Pals de Pe d X RR dE RR cr I t cg ARS 11 ENT la Te sets hor tinge Se RERO RII CREE QS a WERE br AG NG SpA neci RE 11 4 4 Electrical Service Guide ere dau EIER d NEIEN e ex yer nt nie ne ta UE NERA 12 4 5 Connecting 3 Phase Input Power For 460 575 Volt Models 13 4 6 Connecting 3 Phase Input Power For 400 460 Volt Models 14 4 7 Power Source Output Connections ss 15 4 8 Remote 14 Receptacle
35. ve e 9 de o OM 222 166 Page 64 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You 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 expertise of the distributor and Miller is there to help you every step of the way 72 Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructi
36. 4 10 Temperature Recorder Receptacle RC9 Information And Connections 1 Plug 2 Threaded Collar 3 Temperature Recorder Receptacle RC9 See Section 4 11 To connect to receptacle insert plug and tighten threaded collar 803 993 C 4 11 Temperature Recorder Socket Information Socket No Socket Information 1 Thermocouple No 1 TC1 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CJ 2 Thermocouple No 2 TC2 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CJ 3 Thermocouple No 3 TC3 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CJ 4 Thermocouple No 4 TC4 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CJ 5 Signal Common 6 Thermocouple No 5 TC5 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CJ 7 Thermocouple No 6 TC6 0 10 volt dc signal OV 50 F 46 C 10V 1500 F 816 CH 8 Unused 9 Unused 10 Chassis Ground 11 Unused 12 Unused 18 Unused 14 Unused OM 222 166 Page 17 4 12 Secondary Insulation Protection Secondary insulation protection circuitry automatically shuts down the power source output if a potentially hazardous condition exists at the heating device connected to the power source e g insulation has broken down on a heating blanket causing the c
37. 7 RETAINER contact 0 0 hh ha en 1 na EE 221 442 PIN radsok 14 mm cable end 1 PG EEN 225 919 SHELL ASSY connector protective plug 1 OM 222 166 Page 62 Notes SOCKET WRENCH SELECTION TABLE SOCKET WRENCH SELECTION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size U S EE Ze Balt Nut SUN eme Balt Nut 1 4 in 250 in 3 8 in 7 16 in 6mm 2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16 in 1in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22 mm 8661 in 32 mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24mm 9449 in 36 mm 36 mm 1in 1 000 in 1 1 2 in 1 1 2 in OM 222 166 Page 63 Notes DECIMAL EQUIVALENTS Se Oe 5 Se Be Se OS Se Se Se e 9 dez O 6 3 Ze e 6 Se 909 Se e 9 ve 9 0 60 33 BG Se CS 6 eiz Q 9 8
38. 7 Removing Wrapper and Measuring Input Capacitor Voltage Pg Tools Needed CO 5 16 3 8 in o Or Vor CI o O lead to right bus terminal lead to left bus terminal wire wound resistor l Insulation Rating Typical Bleeder Resistor 200 to 500 ohm 10 watt 16 AWG 600 Volts AC A 900 Volts dc can be present on the capacitor bus and significant DC voltage can remain on capacitors after unit is Off Always check the voltage on inverter assembly as shown to be sure the input capacitors have discharged before working on unit A Turn Off welding power source and disconnect input power A 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 Inter
39. 8 Lx DE EEE edente Sone 115443 STAND OFF no 6 32 x 750 lg 250 hex 7 oe OF ee e AEN Are 083147 GROMMET scr no 8 10 panel hole 312 sq 500 high 2 imo ue RTS ran 222 327 THERMISTOR ntc 30 k ohm at 25 deg C 24in lead 1 SUB tae LR DAW 030 170 BUSHING snap in nyl 750 ID x 1 000 mtg hole 1 et E 218 430 COVER access 1 sa NO ie rare 220 825 BUS BAR capacitor 4 11 C7 C10 218687 CAPACITOR polyp film 1 35 uf 700 VAC 5 0 4 11 C7 C10 225775 CAPACITOR polyp film 1 10 uf 700 vac 5 0 400 V model only 4 ele evra TO suu 219 002 TRANSFORMER control 00 0 ccc cece ee eee eens 1 18 PC7 225 558 KIT circuit card assy intrenct srce out 1 14 PCT 217 928 CIRCUIT CARD ASSY power source control 1 A 212038 SCREW M4 7 x 8 5 pan hd phl stl pld slffmg 8 OM 222 166 Page 60 Item Dia Par No Mkgs No Description Quantity Figure 11 9 Left Windtunnel Continued A PLG16 121 122 131054 HOUSING RCPT SKTS SERVICE KIT 3 H PLG19 TO ss 115 094 HOUSING PLUG SKTS SERVICE KIT 2 EEN PLG15 118 115 093 HOUSING PLUG S
40. GND 4 RC13 1525 24 lt RC1 1 GREEN RT HI GT RC13 5 gt amp RC1 4 ISO GND 2 RC13 13 gt 2A lt RC7 1 LFT LO GT RC13 3 gt lt lt RC7 4 ISO GND 1 lg Ee RC7 3 e LFT HI GT RC13 1 gt k RC7 6 TANK VFB RC13 9 53 HAL lt RC4 1 TANK VFB RC13 2035 24 amp RC4 3 po xl RC7 3 x MAT OUTPUT IGBT IFB Rc7 8 S HAT GND RC7 1 gt HAT QUTPUT 1 CT IN RC7 6 sb WHT OUTPUT 1 CT RETURN RC7 2 sb HAT OUTPUT 2 CT IN RC7 7 a WHT OUTPUT 2 CT RETURN 14 CABLE 1 IN a UE T NG FETT OTT TET Roro pe GND E S RR AA S A A RC7 5 gt CABLE 2 IN gt z SS EE EISEN E END K gt VV VV VIN NN NN NN NN RC22 PLG22 17 RC14 24 APAN 12 CONTACTOR B 107 c REF COM 1045p SS COMMAND 1052 E BUFOUTO lt LIMIT 1 1062 F BUFOUTI 75 TANK 2 oe 1V 100A 277 p BUFOUT2 73 LIMIT 2 109 BUFOUTS 7 FREQ 1V 10KHz 108 lt ISOGNDX 75 Pave 1V 10KW Gre BUFOUT4 76 Vrms 1V 100v Geh BUFOUTS lt 7 TANK Irms _ 1V 1004 7740 N BUFOUTS 7g PRIEZ K BUFOUTZ lt 9 ER 218 057 G OM 222 166 Page 49 SECTION 11 PARTS LIST 5 3 CS Hardware is common and not available unless listed See Figure See Figure 11 2 804 218 D Figure 11 1 Wrappers Item Dia Part No Mkgs No Description Quantity Figure 11 1 Wrappers E S 217470 PANEL side HEH oia a ea dang Ee ha eg 1 DP 217 860 LABEL warning electric shock and input pwr FR 1 o 217325 COVER TOP xus eee RE rere p ek E ER RA
41. I Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org fer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following proce dures 1 Arrange output cable to one side and away from the operator 2 Do not coil or drape output cable around the body 3 Keep power source and cable as far away from the operator as practical About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 222 166 Page 3 SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION ihom 2007 04fre A Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 2 1 Signification des symboles Q DANGER Indique une situation dangereuse qui si on Indique des instructions sp cifiques l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles 2 joints ou sont expliqu s dans le texte EX A Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessur
42. IED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informat
43. Increase Or O Decrease button changes the segment type to Step Ramp Soak or End The functions of each segment type are as follows N Step increases the temperature in the part at full programmed power A maximum temperature of 1450 F 788 C can be programmed Ramp increases or decreases the temperature in the part at a controlled rate in degrees per hour A maximum temperature of 1450 F 788 C and a maximum rate of 9999 F hr 5555 C hr can be programmed Soak will hold the temperature for a programmed time A maximum hold soak time of 99 59 hours minutes can be programmed End is programmed to indicate the completion of the cycle and termination of output power Step Function When type is set to Step the following screen appears on the display Custom Program Screen Mode Custom Program Segment 1 Type gt Step Temperature 600 Pressing the Cursor button again automatically advances the program to the next segment number a Ramp Function When type is set to Ramp the following screen appears on the display OM 222 166 Page 29 Custom Program Screen Mode Custom Program Segment 1 Type Ramp Temperature 600 Ramp Rate 600 Hr Use the Cursor O button to set the desired value O button to move the cursor to the Temperature or Ramp Rate position and use the Increase or Decrease When the cursor is in the Ramp Rate pos
44. KTS SERVICE KIT 2 DU sida PLG77 119 115 092 HOUSING PLUG SKTS SERVICE KIT 2 e PLG17 115091 HOUSING PLUG SKTS SERVICE KIT 1 Run se PLG18 T46 iu 131 056 HOUSING RCPT SKTS SERVICE KIT 2 TUNES PLG13 113 162 382 HOUSING PLUG SKTS SERVICE KIT 2 EE ba PLG14 130203 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 222 166 Page 61 F Hardware is common and not available unless listed 804 300 A Figure 11 10 Hermaphroditic Blank Plug Assy Item Dia Part No Mkgs No Description Quantity Figure 11 10 Hermaphroditic Blank Plug Assy ou BAN An emi 221 440 O RING o9 IDx109CR eee 2 i2 a degt 221 443 SOCKET ASSY radsok 14 mm cable end 1 E EE 221 099 CLAMP strain relief 2 EE WEE 136 343 SCREW K50 x 20 pan hd phl stl pld pt 2 e dr 224 261 CAP plug assy 1 Cg APP DRE 221 438 COLLAR coupling 1 aa EE 221 43
45. N If no fault or limit conditions are present system status lights are not illuminated The system has a hold function that will maintain a temperature or hold the soak time of any active temperature controlled program Pressing the Hold O button will only activate the hold function while in the run mode If the system is not in the run mode the following screen will appear on the display Hold Message Screen Must be running to enter Hold mode OM 222 166 Page 35 button is not functional If the system is running in Manual operating mode button will cause the following screen to appear on the display Hold Message Screen Hold mode not available when temperature control is not active To make changes to a program while in run mode press the Hold button yellow indicator LED will turn off When in hold the system will maintain the actual temperature of the hottest thermocouple while the program is being changed O N Press the Program as 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 Custom Program button to move the cursor to the parameter that will be changed O e or Decrease NA button to make desired changes KB the Hold button yellow indicator LED will turn off Any program parameter temperatures rates times or number of TC s can be changed while in hold In a custom
46. NDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPL
47. RC14 Information and Connections 000 cece eee eee ee 16 4 9 Remote 14 Socket Information 16 4 10 Temperature Recorder Receptacle RC9 Information And Connections 17 4 11 Temperature Recorder Socket Information 17 4 12 Secondary Insulation Protection 18 4 13 115 Volt AC Duplex Receptacle And Supplementary Protector 19 4 14 Locating Thermocouples 19 4 15 Attaching Welded Thermocouples 21 4 16 Using Contact Thermocouples 22 4 17 Placing Temperature Probe 22 SECTION 5 COMPONENTS AND CONTROLS 23 Sr TA CONTOS s street Dee EE Mita tana hen aie TTT 23 SECTION 6 SETUP AND OPERATION EEN 24 6 12 Safety Equipment o5 A A dE BOE Ae Me ROMA EE 24 6 2 System Description sr eer aede hws hae RYE te Sa wee TE en ra tae 24 6 3 Power Source System Setup 24 G A Programming e Naa LANG NEEN EEN Seo Eb KARL ea EG cede ERE RE EE EORR RUE kaha 26 6 4 1 Temperature Based Contra 26 6 4 1 1 Preheat cise tie a EEN ora cha ee en E Ro RS ee nee Ea ROTE e 26 6 4 1 2 Bake Out is rep FERRE Mel ENT eh Rae dae AA ee ais 27 6 4 1 3 PWHT Post Weld Heat Treat 0 III 27 6 4 1 4 Custom Program error ge eee tar akin ons Eland Ea ato sew awe ad 28 6 4 2 Manual Control din ad nene
48. Replacement Parts Model and serial number required when ordering parts from your local distributor OM 222 166 Page 51 F Hardware is common and not available unless listed 804 220 A A Figure 11 3 Rear Panel Item Dia Par No Mkgs No Description Quantity Figure 11 3 Rear Panel MD LAT NIE Ac ERAN 217 324 5 PANEL TEA 1 RE BKA EE aa 1 2 RC1 174 207 RECEPTACLE str dx grd 2P 3W 15A 125V 1 BE or tu diues uten 127 837 RECEPTACLE tw Ik insul fem dinse type 2 mad say e lt 1 EE 089 807 SUPPLEMENTARY PROTECTOR man reset 1P 2 5 A 250 VAC 1 on aia PAA 220 824 COVER receptacle weatherproof duplex 1 DM ib pala 218 689 PANEL rear output iraia X TR XS RL ae 1 e AN EE 602 498 LABEL danger high voltage 1 Lx o E E 010 467 CONNECTOR clamp cable 1 250 1 9 RC14 143976 RCPT W SKTS service kit 1 10 RC9 047 636 HOUSING PLUG PINS service kit 1 Bana ANE 224 989 RECEPTACLE ASSY output with leads 2 Mya NONG a GP NAL AN LLANA 234 531 SHELL w contact pin and socket service kit for 224 989 0 d PANA RES 224 042 CONNECTOR circ CPC protective cap 1 ced CA 170 391 CONNECTOR circ MS protectiv
49. Should a fault condition occur the output is immediately turned off the red Fault LED flashes and the Stop 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 O display If the active screen is Program press the Run Status button to display the fault condition O Pressing the Decrease button will acknowledge the fault and the red Fault LED will stop flashing and remain on continuously However the button LED will continue to flash indicating that the process has stopped O 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 9 5 Fault Condition Codes Fault Condition Additional Information F51 Thermocouple 1 Internal Fault Service required F52 Themocouple 2 Internal Fault Service required F53 Thermocouple 3 Internal Fault Service required F54 Thermocouple 4 Internal Fault Service required F55 Thermocouple 5 Internal Fault Service required F56 Thermocouple 6 Internal Fault Service required F57 CJT Sensor Internal Fault Service required F58 Output Voltage Fault Service required F59 Output Current Fault
50. a o suis ete eds 605 339 WASHER TOOTH 377 ID X 0 507 OD X 022T stl pld 2 ee pae ex 098 691 STAND OFF NO 6 32 X 500 LG 250 hex stl mart 6 Aa td dto 217 326 BRACKET TC interface 1 Den EK 218 691 INSULATOR tank cap 1 10 PC5 225 556 KIT circuit card assy intrenct bridge 1 eh WEEN POB EE 216 207 CIRCUIT CARD ASSY TC interface 1 ide ioe a N AOR 208 591 SCREW M 5 8X 12 soc hd torx stl pld sems 12 MSc edes 212038 SCREW M4 7 x 8 5 pan hd phl stl pld 8 GG BN sux 225 514 FUSE crtg 2 amp 600 V time delay 1 EK EE 225 553 HOLDER fuse crtg 30 A 600 V 13 32 X 1 1 2 LG 1 PLG32 115091 HOUSING PLUG SKTS SERVICE KIT 1 JE oe PLG33 38 54 181 204 HOUSING PLUG SKTS SERVICE KIT 7 ha PLG51 57 115 093 HOUSING PLUG SKTS SERVICE KIT 2 DTE PLG58 115094 HOUSING PLUG SKTS SERVICE KIT 1 tee listes 227 082 CHOKE common mode 400 V model only 1 Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial numbe
51. and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when using induction heating equipment To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using a cable cover OM 222 166 Page 40 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment install test and service H F producing units e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference READ INSTRUCTIONS e Use Testing Booklet Part No 150 853 when servicing this unit e Consult the Owner s Manual for induction heat ing safety precautions e Use only genuine replacement parts from the manufacturer For Gasoline Engines A Engine
52. azardous ld Induction Heating of certain materials adhesives and fluxes can produce fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation to re move fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instruction for adhesives fluxes metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watchperson near by Fumes and gases from heating can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not heat in locations near degreasing cleaning or spraying oper ations The heat can react with vapors to form highly toxic and irritating gases e Do not overheat coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the 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 222 166 Page 1 FIRE OR EXPLOSION hazard e Do not overheat parts e Watch for fire keep e
53. b e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving an induction heating power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Troubleshooting Section be fore touching any parts P STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling TIN boards or parts Ve e Use proper static proof bags and boxes to store move or ship PC boards FIRE OR EXPLOSION hazard e Do not place unit on over or near combustible surfaces e Do not service unit near flammables OM 222166J 2007 06 safety ihim 2007 04 7 Indicates special instructions e Le D we This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards FLYING METAL or DIRT can injure eyes uou e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Do not touch or handle induction head coil during operation e Keep meta
54. based program any segment num ber can be changed however if the operation of a segment has already been completed in a program the change to that segment will not affect the program function e Press the Stop button to end the program OM 222 166 Page 36 6 9 System Operating Characteristics The power source delivers a high frequency alternating current output that energizes the coil creating the magnetic field used to heat the workpiece The power source output characteristics are a function of the configuration type and number of coils used as shown in the following table Table 6 1 Power Source Output Characteristics Output Type Maximum Amperage Maximum Voltage Frequency Range 250 A per output for 15 minutes After 15 minutes power steps 3 down to limit current to 150 am 700 V 5 25 7 kHz Air Cooled Single and Dual peres per output for continuous operation See Note 1 700 V 25 7 30 kHz E 350A 700 V 5 20 kHz Single Liquid Cooled See Note 2 700 V 20 30 kHz m 350 A per output 700 A total 700 V 5 20 kHz Dual Liquid Cooled See Note 2 700 V 20 30 kHz ni Note 1 In the fi E ote 1 In the frequency range Air Cooled Output of 25 7 to 30 KHz the maxi mum output amperage de 25077 creases linearly from 250 down to 175 amperes per output Re gardless of frequency after 15 amp 200 minutes the maximum output is a r
55. by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Do not touch input capacitor s Allow time for capacitor s to discharge Check input capacitor s voltage see Section 9 7 227 085 A OM 222 166 Page 8 3 3 Rating Label For CE Products MILLER ELECTRIC MFG CO APPLETON WI USA 907298 SERIAL OEE ro A IE la DEBE TAYA 2 TI 7ooa WS rov D i U1 400 460 l1max 50A 2x17 50 60 Hz 115V EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 226534 B IE For label location see Section 4 2 226 534 B 3 4 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information OM 222 166 Page 9 3 5 Symbols And Definitions Some symbols are found only on CE products A Amperes V Volts ING Alternating Current X Duty Cycle Degree Of a n E p Protection H Z Hertz Circuit Protection Output Increase d i Line Connection 1 Primary Current L Rated Current C U Primary Voltage U Load Voltage b Read Instructions Three Phase Static Frequency Con verter Transform er Frequency Con V
56. connect Board PC4 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC4 as shown until voltage drops to near O zero volts 7 If the capacitor voltage does not drop to near zero after several minutes use a bleeder resistor of between 200 and 500 ohms at least 10 watts and 16 AWG 600 volts ac in sulation rated wire to discharge the capacitor s 3 Typical Bleeder Resistor An example of a typical bleeder resistor is shown on this page Proceed with job inside unit Re connect FM3 and reinstall right side panel when finished j E 804 519 B OM 222 166 Page 46 9 8 Blowing Out Inside Of Unit A Turn Off welding power RIR source and disconnect input power A Remove wrapper and be sure input capacitors are discharged Blow out inside of unit Blow out fan motors in right side panel and front panel 804 625 B Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 222 166 Page 47 SECTION 10 ELECTRICAL DIAGRAM WARNING 7 ELECTRIC SHOCK HAZARD e Do not touch live electrical parts
57. dware is common and not available unless listed 804 219 A Figure 11 2 Front Panel Item Dia Par No Mkgs No Description Quantity Figure 11 2 Front Panel e fetch IU AO 217 323 5 PANEL front An els LAG Baa he GA AKALANG NG 1 mE 216 225 NAMEPLATE ProHeat 35 1 KA EE 216 224 PANEL operator interface 1 4 TC1 TC6 218686 RECEPTACLE ASSY thermocouple 6 hens lt ety ta cS 217327 PLATE TC receptacle ier IR LAE Yun ade YE LA Ya os 1 276 voor 9d uud 213 060 SWITCH tgl 3pst 60 A600 VAC 1 EPA 212 810 LABEL on off w symbols 1 D A 221 493 LABEL TG T26 issus NG paa a dC cre A Ra RG 1 MOD POT EPEKTO 115 440 STANDOFF no 6 32 2 cnet a a 14 De NO EE 224 143 GASKET meter lens 1 11 PC8 216 068 CIRCUIT CARD ASSY display 1 sw A228 LO vs 216 072 CIRCUIT CARD ASSY operator interface 1 saa NO man detracta 148 297 NUT 006 32 31 hex 20 Stl pld eee nee 2 MANA BAHA PLG24 115091 HOUSING PLUG SKTS SERVICE KIT 1 Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested
58. e cap 1 sb LA 147 195 NUT 375 27 54 hex 25 H nyl 1 dA RC21 22 135635 HOUSING PLUG PINS SERVICE KIT 2 DEER PLG21 22 131 054 HOUSING RCPT SKTS SERVICE KIT 2 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 222 166 Page 52 F Hardware is common and not available unless listed 804 221 D Figure 11 4 Base w Components Item Dia Par No Mkgs No Description Quantity Figure 11 4 Base w Components IEEE 217328 ERAME lifting oia eom eb e tcd edet eee fu Ens art dee Us 1 vob wan euge 213 865 BASE ASSY ios a eie ter aree 1 E ania 213939 LABEL warning electric shock can kill significant 2 AA EL 2 18 092 3 INDUGTOR a a pa A e 2 Dia 216 815 BRACKET cap support cece eee 1 S0 2012 sase 213 870 GAPACITOR elciit acre cee tease ges nus ane be rade teats nab dus 2 ed usn TA inui 213583 TRANSFORMER he 1 RO bed uS 227 065 TRANSFORMER hf 400V model 1 OBE L E 216 629 14 BRACKET fan 0 fate dE San pre Eeer 1 9 FM1 FM2 222728 FAN nuffin 48V hen 2 10 RC4 115
59. ect NG Na NONA 223 120 BLOCK term 115 amp 3 pole screw term 1 E NEE 115 443 STAND OFF no 6 32 x 750 lg 250 hex 5 E EE 148 743 LUG univ w scr 600V 2 14 wire 250 stud 1 Pa Ba RTT s 222 326 THERMISTOR ntc 30 k ohm at 25 deg C 34in lead 1 E APA REESE 083147 GROMMET scr no 8 10 panel hole 312 sq 500 high 2 AMO T 224 391 PANEL insulating mtg capacitor cee ee eee 1 Lac WEEN 605 339 WASHER TOOTH 377 ID X 0 507 OD X 022T stl pld 2 12 PC4 228 407 KIT circuit card assy intrenct srce inpt 1 cT 212038 SCREW M4 7 x 8 5 pan hd phl stl pld 2 sp E sme eee 176 879 SCREW M5 8x 12 hex hd phl 8 8 pld 12 a EE 228 262 CIRCUIT CARD ASSY bus intrenct 1 a ANA we 208 591 SCREW M 5 8X 12 soc hd torx stl pld sems 14 OM 222 166 Page 56 Item Dia Part No Mkgs No Description Quantity Figure 11 7 Right Windtunnel Continued RE 229 728 STRAP connecting a ER AT 216 262 CIRCUIT CARD ASSY cooler control SIGE MAN AHA NING 030 170 BUSHING snap in nyl 750 id x 1 000 mtg hole RA ALAGANG 291 050 i ASSY resIstol
60. ecurely in place MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations IDT OVERUSE can cause OVERHEATING e Allow cooling period D Reduce output or reduce duty cycle before p starting to heat again e Follow rated duty cycle 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 222 166 Page 2 P STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling IS boards or parts Eo e Use proper static proof bags and boxes to store move or ship PC boards E E H F RADIATION can cause interference e High frequency H E can interfere with radio navigation safety services computers and communications equipment e Have only qualified person familiar with electronic equipment
61. educed to 150 amperes per tl rac eat cn NA PA PA AA KR EY output D o amp 150 aj o o E x 1004 bal 507 n 5 Frequency KHz 400 IA EF Note 2 In the frequency range Liquid Cooled Output of 20 to 30 KHz the maximum 350 output decreases linearly from 350 down to 175 amperes per output _ 300 D i I I 8 250 5 i n I 2 200 or AO EE te Sen den OU SE NS o I Z 150 lt i x I i 100 50 B 5 20 30 Frequency KHz OM 222 166 Page 37 SECTION 7 MAINTENANCE 7 1 Routine Maintenance AE 2 pu A Disconnect power before maintaining gt Maintain more often during severe conditions Q Inside Unit Check Change Q Clean Replace Reference A To be done by Factory Authorized Service Agent Every PRE Ja Section 4 7 3 4 12 Months d Damaged or Unreadable Q Output Connector Con Q Ground Sense Lead Re Q Operator Interface Over Labels tacts ceptacles lay 2 1 pa eu Integrity Of Protective Cracked Cables Plug Replace If Necessary Every Section 9 8 6 Months OM 222 166 Page 38 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING A Protect yourself and others from injury read and follow these precautions
62. em MUST be placed on the unused output connector or the system will not operate If two output extension cables are used they both MUST be of the same type either both air cooled or both liquid cooled or the system will not operate in this case the protective plug is not used When two extension cables and heating devices are utilized on the system the extension cable lengths and heating devices MUST be identical see Section 4 7 The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal tempera tures reach or exceed specific set limits see Section 9 6 3 Power Source System Setup To view the System Setup screen simultaneously press the Parameters buttons and the following screen will appear on the display System Setup Screen Degree Units gt F SYSTEM SETUP Tolerance t25 Backlight Yes Input Type K TC Control Mode Manual Power Output 35 KW System Lock No To change a setting O e Press the Cursor button to move the cursor to the parameter to be changed D KB e Press Increase AN or Decrease NS button to select desired set up feature OM 222 166 Page 24 Possible selections Degree Units F C Tolerance 5 to 99 in F 3 to 55 in C Backlight Yes No Input Type K TC Control Mode Temp Time Manual Power Output 1 to 35 System Lock Yes No Degree Units press the Increase AN or
63. er cannot be turned off while output is on OM 222 166 Page 34 x The Cooler button is inactive when no cooler is detected and no liquid cooled output cable is attached 6 8 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 LED s illuminate and the following screen appears on the display Power Up Message Screen ProHeat Firmware Revision X XX Copyright c 2005 Miller Electric Mfg Co X XX indicates the firmware revision number installed in the unit If an error is detected during the check routine the system fault LED illuminates and an error message screen appears on the display see Section 9 5 When the check routine is completed successfully the operator interface defaults to the following e The Stop button indicator LED illuminates to indicate no heating cycle is in process N The temperature displays indicate actual temperature from the TC s thermocouples If no thermocouples are connected the displays indicate OPEN N Control LED S illuminate to indicate the number of control TC s in the last program e The appropriate degree units F or C light illuminates O N The display defaults to the Run Status screen from the last program used and the Run Status button indicator LED illuminates
64. erter Rated Maximum Maximum Power O Supply Current Consumption DING Three Phase Yo Percent 1max 1max Remote O Panel Local E High Temperature SCH Voltage Input O Off On 4 1 Specifications Amperes Input at Rated Load Output oi Rated Output Required 50 or 60 Hz Overall id etlective Three Phase R eight Frequency ana Gg Inductance Dimensions ingle ua Output Output 400V 460V 575 V kVA kW 35 kW At ae Length 36 3 4 in 10096 Duty Cycle y 993 mm 5 To 30 Cycle 2 5 To 50 Width 21 1 2 in 227 Ib kHz 350 a uh SUA 20 OSEE ME 546 mm 103 kg RMS 700 pus Si Height 29 in V RMS RMS 737 mm Storage Temperature Range 40 F 40 C to 122 F 50 C While idling OM 222 166 Page 10 4 2 Selecting A Location EZ ee SR in Movement Location And Airflow INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE NA 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Plate Label CE Models Only Label located under power switch 5 Rating Label CE Models Only Use rating label to determine input power needs 6 Line Disconnect Device Locate unit near correct input power supply A Spec
65. es graves Les dan Ce groupe de symboles veut dire Avertissement Attention DANGER gers possibles sont montr s par les symboles joints ou DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES sont expliqu s dans le texte CHAUDES Consulter les symboles et les instructions ci dessous y NOTE indique des d clarations pas en relation avec des blessures aff rant pour les actions n cessaires afin d viter le danger personnelles 2 2 Dangers relatifs au soudage l arc A i Pek SES e Installer le poste correctement et le mettre la terre convenable Les symboles presentes ci apres sont utilises tout au long du ment selon les consignes du manuel de l op rateur et les normes pr sent 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 mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la que r sumer l information contenue dans les normes de s cu borne de terre du sectionneur ou que la fiche du cordon est raccor rit num r es la section 2 5 Veuillez lire et respecter toutes dee une prise correctement mise la terre ces normes de s curit e En effectuant les raccordements d entr e fixer d abord le conduc
66. for open temperature sensor and repair Change to back up temperature sensor L04 Thermocouple 4 Open Check for open temperature sensor and repair Change to back up temperature sensor L05 Thermocouple 5 Open Check for open temperature sensor and repair Change to back up temperature sensor L06 Thermocouple 6 Open Check for open temperature sensor and repair Change to back up temperature sensor 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 LO9 Output Current Limit Tighten blanket against pipe surface L10 Output Current Limit Increase number of turns Decrease coil space Tighten cable on insulation OM 222 166 Page 42 Limit Condition Additional Information L11 Coolant Overtemp Limit Check coolant flow and level Clean coolant filters and heat exchanger Increase number of turns Verify appropriate insulation thickness L12 Power Source Overtemp Limit Check for blocked vents Clean wind tunnel heat sinks L13 Cable Connection Check for loose open output connection Verify all output cables are same type Verify receptacle plug connected 9 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
67. he responsible Business Unit s located at the manufacturing facility dec stat 1 07 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING ihom 2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 A A NOTICE Indicates statements not related to personal injury Symbol Usage DANGER Indicates a hazardous situation which if 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 plained in the text 1 2 Induction Heating Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away 9 ELECTRIC SHOCK can kill PN Touching live electrical parts can cause fatal shocks or severe burns The power circuit and output bus bars or connections are electrically live whenever
68. hermocouples and the sensor can be moved during the preheat process to check temperatures at other locations on the joint E Removing the contact probe will display a short duration of heat drop on the temperature recorder if used The contact temperature sensor can be plugged into the thermocouple extension cable or a Type K 25 ft armored extension cable can be used One of these extensions is required for each sensor In preheating applications the thermocouple must be placed under the induction coil Temperatures at the weld joint can be checked with temperature sensitive crayons to verify the preheat temperature Welded thermocouples are normally used in stress relieving applications due to their accuracy See product literature for item part number 4 17 Placing Temperature Probe 1 Blanket 2 Temperature Probe Place temperature probe between blanket and metal material The probe must be in contact with the material being heated The tip of the probe should be positioned in the approximate center of the blanket anywhere along the blanket length 804 321 A OM 222 166 Page 22 SECTION 5 COMPONENTS AND CONTROLS 5 1 Controls 4 5 6 7 10 G 19 B o o 099 o 099 099
69. ial installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 803 992 B 4 3 Tipping Do not move or operate unit where it could tip OM 222 166 Page 11 4 4 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 branch circuit sized for the rated output and duty cycle of the welding power source 50 Hz Three 60 Hz Three Phase Phase Input Voltage 400 460 575 Input Amperes At Rated Output 60 50 40 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 Time Delay 2 70 61 45 Normal Operating 3 80 70 60 Min Input Conductor Size In AWG 4 6 8 8 Max Recommended Input Conductor Length In Feet Meters mea 65 DE Min Grounding Conductor Size In AWG 4 8 8 10 Reference 2005 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 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable betwee
70. ield Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTE
71. ifi cation information 7 The system is equipped with 3 pin thermocouple connections at the front of the unit Six thermocouples can be attached to the power source The system is equipped with 3 pin connectors to accommodate shielded extension cables The shielded cables protect from electrical interference 8 Type K thermocouple wire has a positive and negative wire The positive wire is marked as solid yellow or striped yellow The connector screw terminals are marked positive and negative Be sure to attach the wire to the connector with proper polarity OM 222 166 Page 19 9 The following describes the thermocouple routing from work to power source e Type K thermocouple wire two wire is attached directly to the workpiece using a Thermocouple Attachment Unit see next section for information on attaching thermocouples The other end is fitted with a 2 pin type K connector e The 2 pin connector plugs into the 3 pin composite extension cable The extension cable has a six channel block of 3 pin female connectors The pin size locates the position of the 2 pin connector on the extension The extension cable contains six 3 wire bundles of shielded cable e The 3 pin male extension cable plugs into the 3 pin female connector on the front of the power source
72. ion and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mig Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com 72 Miller
73. is process is selected the following screen appears on the display Bake Out Screen Mode Bake Out Control TC gt 1 Soak Temp 600 Soak Time 01 00 00 Cool Temp 200 Cool Rate 600 Hr O O The default position of the cursor is next to Control TC Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1 2 3 or 1 2 3 4 TC1 MUST always be a control thermocouple TC2 thru TC4 can be used for controlling or monitoring When a thermocouple is selected as control the LED adjacent to the seven segment display illuminates Use the Cursor button to move the cursor to the desired selection Soak Temperature Soak Time Cool Temperature or Cool Rate and O O press the Increase or Decrease button to change the value to the desired setting The minimum and maximum soak temperature settings for bake out are O and 1000 F 18 and 538 C The minimum and maximum soak times are O and 1000 hours The minimum and maximum cool rates are 10 and 9999 7hr When the system is utilizing air cooled blankets the maximum temperature setting is 400 F 204 C If the program setting is above 400 F 204 C the following screen will appear on the LCD display when the Run button is pressed Maximum Temperature Message Screen Cannot enter Run mode Programmed temperature settings exceed air cooled limits 400 F 204 C
74. isateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer regulierement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Nutiliser que les pi ces de rechange recom mand es par le constructeur 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimiques dont l Etat de Californie reconna t qu ils provoquent des can cers et des malformations cong nitales ou autres problemes de procr ation Se laver les mains apr s manipulation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com OSHA Occupa
75. ition pressing the Cursor button again automatically advances the program to the next segment number Notes OM 222 166 Page 30 Soak Function When type is set to Soak the following screen appears on the display Custom Program Screen Mode Custom Program Segment 1 Type gt Soak Soak Time 00 01 00 Use the Cursor O O button to move the cursor to the Soak Time position and use the Increase or Decrease button to set the desired value When the cursor is in the Soak Time position pressing the Cursor button again automatically advances the program to the next segment number End Function When type is set to End the following screen appears on the display Custom Program Screen Mode Custom Program Segment gt 2 Type End Control TC 1 The only changeable parameter in the End segment is selecting the number of thermocouples Use the Cursor button to move the cursor O O to the Control TC position Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1 2 3 or 1 2 3 4 TC1 MUST always be a control thermocouple TC2 thru TC4 can be used for controlling or monitoring When a thermocouple is selected as control the LED adjacent to the seven segment display illuminates O A custom program ca
76. l jewelry and other metal personal items away from head coil during operation e Allow cooling period before working on equipment e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns EXPLODING PARTS can cause injury e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing e Turn Off induction heating power source be fore making or changing meter lead connec tions e Use at least one meter lead that has a self retaining spring clip such as an alligator clip e Read instructions for test equipment FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OM 222 166 Page 39 d MOVING PARTS can cause injury Keep away from moving parts such as fans Ng e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power MAGNETIC FIELDS can affect Implanted Medical Devices
77. lay Preheat Screen Mode Preheat Control TC 1 Temperature 400 Soak Time 01 00 00 O O The default position of the cursor is next to Control TC Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1 2 3 or 1 2 3 4 TC1 MUST always be a control thermocouple TC2 thru TC4 can be used for controlling or monitoring When a thermocouple is selected as control the LED adjacent to the seven segment display illuminates Use the Cursor O button to move the cursor to the desired selection Temperature or Soak Time and press the Increase or O Decrease NA button to change the value to the desired setting The minimum and maximum temperature settings for preheat are O and 1000 F 18 and 538 C The minimum and maximum soak times are 0 and 1000 hours When the system is utilizing air cooled blankets the maximum temperature setting is 400 F 204 C If the program setting is above 400 F 204 C the following screen will appear on the LCD display when the Run button is pressed Maximum Temperature Message Screen Cannot enter Run mode Programmed temperature settings exceed air cooled limits 400 F 204 C OM 222 166 Page 26 6 4 1 2 Bake Out The bake out process allows the operator to program a temperature and soak time as well as a cooling rate from bake out if desired When th
78. ly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet E Indicates special instructions e pnm T Y This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e When making input connections attach proper grounding conductor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring re place cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body Do not touch power circuit if you are in contact with the work ground or another power circuit from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place SIGNIFICANT DC VOLTAGE exists in inverter type power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any internal parts FUMES AND GASES can be h
79. minimum and maximum soak times are 0 and 100 hours When the system is utilizing air cooled blankets the maximum temperature setting is 400 F 204 C If the program setting is above 400 F 204 C the following screen will appear on the LCD display when the Run button is pressed Maximum Temperature Message Screen Cannot enter Run mode Programmed temperature settings exceed air cooled limits 400 F 204 C 6 4 1 4 Custom Program In Custom Program the operator can create a custom program with multiple steps or nonsymmetrical heat treat programs where the heating and cooling rates and temperatures are different When this process is selected the following screen appears on the display IS This is the screen for initial use of the system Subsequent use of custom program will revert to the last program used OM 222 166 Page 28 Custom Program Screen Mode Custom Program Segment 1 Type End Control TC 1 O O The default position of the cursor is next to Segment Press the Increase or Decrease button to increase or decrease the segment number unless the segment type is End In this case the segment number will advance to segment 1 Use the Cursor O button to move the cursor to the desired selection Type or Control TC and press the Increase or Decrease O O button to change the value to the desired setting When the cursor is moved to the Type selection pressing the
80. n contain up to 10 segments To view Program parameters position the cursor at segment and use the Increase Or O Decrease button to advance through the segment numbers until the End segment When a segment number is changed appropriate segment parameter information appears on the display OM 222 166 Page 31 Typical 5 Segment Custom Program Custom Program Screen Mode Custom Program Segment 1 Type gt Step Temperature 600 Temperature increases to 600 degrees at full programmed power Custom Program Screen Mode Custom Program Segment 2 Type Ramp Temperature gt 1250 Ramp Rate 600 Hr Controlled heating to 1250 degrees F at a ramp of 600 degrees per hour Custom Program Screen Mode Custom Program Segment 3 Type Soak Soak Time gt 01 00 00 Soak at 1250 degrees F for a period of 1 00 Custom Program Screen Mode Custom Program Segment 4 Type gt Ramp Temperature 600 Ramp Rate 600 Hr Controlled cooling to 600 degrees F at a rate of 600 degrees per hour Custom Program Screen Mode Custom Program Segment 5 Type End Control TC 1 End segment ends the heat treat cycle Controller is programmed to control the process using four thermocouples 6 4 2 Manual Control Manual control allows programming of a specific power level for a specific
81. n the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Notes OM 222 166 Page 12 4 5 Connecting 3 Phase Input Power For 460 575 Volt Models 2 Installation must meet all National maba and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in GND PE Earth Ground put power before connecting input conductors from unit Make input power connections to the welding power source first 3 N Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal E The circuitry in this unit automatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to either 460 or 575 VAC input power See rating label on unit and check input voltage available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 4 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Inp
82. onductor to come into contact with the workpiece or a heating coil touches the workpiece causing a short in the output circuit The supplied ground lead s must be connected between the workpiece and power source to provide proper secondary insula tion protection from a short in the output circuit For single output only one ground lead is required For dual output use both ground leads 1 Receptacles 2 Plug To connect plug align key with key way insert end into receptacle and rotate plug until tight 3 Handle 4 Magnet The secondary isolation magnet must be in contact with bare metal free from rust paint grease etc 5 Workpiece Use handle to place magnet on the workpiece 803 994 B Ref 801 826 C Ref 801 828 C OM 222 166 Page 18 4 13 115 Volt AC Duplex Receptacle And Supplementary Protector 1 115 VAC 2 5 A Single Phase AC Receptacle RC1 2 Supplementary Protector CB1 2 5 A The receptacle supplies nominal 115 volts ac auxiliary power for use with the optional digital recorder Maxi mum output from receptacle is 2 5 amperes CB1 protects 115 volt receptacle RC1 from overload If CB1 opens RC1 does not work y E GI i
83. onnect air cooled output extension cables to Output Connector 1 and Output Connector 2 Dual Liquid Cooled Output Connection Connect liquid cooled output extension cables to Output Connector 1 and Output Connector 2 EF Extension cables must be the same length 25 ft 7 6 m or 50 ft 15 2 m OM 222 166 Page 15 4 8 Remote 14 Receptacle RC14 Information and Connections o o Plug Threaded Collar Keyway Remote 14 Receptacle RC14 See Section 4 9 To connect to receptacle align key way insert plug and tighten threaded collar BOND A 803 993 C 4 9 Remote 14 Socket Information Socket A remote 14 Socket Information A 24 volts dc B Remote Contactor Contact closure to A completes 24 volts dc contactor control circuit C Command reference 10 volts dc D Control circuit common E Remote Output Control Input command signal potentiometer wiper or 0 to 10 volts dc G Not used EJ Power Source Limit Absence of internal contact closure between F and J signals power source error to remote control device H Not used l Actual frequency output signal 1 volt 10 kHz L Average power output signal 1 volt 10 kW M Remote Metering Voltage output signal RMS 1 volt 100 volts N Total current output signal RMS 1 volt 100 amperes K Chassis common OM 222 166 Page 16
84. ons on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models F
85. ooled cable e LQD for a liquid cooled cable PLUG for a protective plug OM 222 166 Page 44 CintFR OPEN no cable or plug in place This is the coolant flow rate in GPM from the cooler on a liquid cooled system ClrSts This is the status of the cooler Possible labels O The second diagnostic screen is available by again pressing and holding the Run Status button and pressing the Parameters button Off Flowing System Diagnostic Screen VLnA B 460V Therml 75 DIAG2 VLnB C 460V Therm2 75 Therm5 OPEN VLnC A 460V Therm3 75 ClrTmp 77 VBus 650V Therm4 OPEN RmtFlw Off VLnA B This is the phase to phase line voltage between phases A and B VLnB C This is the phase to phase line voltage between phases B and C VLnC A This is the phase to phase line voltage between phases C and A VBus This is the DC bus voltage Therm1 This is the temperature of the current source primary heatsink Therm2 Therm3 Therm4 Therm5 ClrTmp RmtFlw This is the temperature of the bridge heatsink This the the temperature of the current source secondary heatsink Open not used Open not used This is the temperature of the coolant on a liquid cooled system OPEN no cooler is detected This is the status of the relay contacts for remote coolant flow on a liquid cooled system OFF ON EF RmtFlw feature is unsupported on the current platform OM 222 166 Page 45 9
86. opped TC5 and TC6 display the temperature of thermocouples 5 and 6 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 6 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 In addition temperatures of thermocouples TC5 and TC6 are also displayed The Parameters screen is for monitoring purposes only and has no selectable or changeable parameters Parameters Screen Power 0 0 KW TC5 17 Current OA TC6 77 Voltage 0 V Frequency 4 5 KHz 6 7 Cooler The Cooler button is used to turn the cooler On or Off on systems using liquid cooled output cables Systems using liquid cooled output cables will not deliver output unless the cooler is On If the cooler is not started prior to initiating a heating cycle the system will automatically start the O O cooler when the Run button is pressed Pressing the Stop button does not shut off the cooler The cooler must be shut off separately by pressing the Cooler button When power source output is energized the cooler cannot be turned off If the Cooler button is pressed while output is energized the follow ing screen will appear on the display Cooler Message Screen Cool
87. per form this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If notified by the FCC about interference stop using the equip ment at once e Have the installation regularly checked and maintained e Keep high frequency source doors and panels tightly shut READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Re gion 5 Chicago is 312 353 2220 website www osha gov National Electrical Code
88. period of time When this process is selected the following screen appears on the display OM 222 166 Page 32 Manual Program Screen Mode Manual Power 0 0 KW Command 0 0 KW Current OA Run Time 00 03 00 Voltage 0 V Frequency 4 5 KHz The only programmable selections are Command power and Run Time Command can be adjusted to deliver up to 35 KW based on maximum power selected in the set up screen for a period of up to 99 hours 59 minutes 59 seconds Power source operating power current voltage and frequency are shown on the right hand side of the display To reset the system back to factory default settings turn off the power source and wait until the display goes blank Turn on the power source When O O the display lights press and hold the Increase and Decrease buttons A message will display Press Program to reset factory D O defaults Release the Increase AN and Decrease buttons and press the Program 6 5 Run Status Run status allows the operator to check status of a program during in process heating Depending on the control mode Temperature or Manual and the temperature based mode Preheat Bake Out PWHT or Custom different style screens appear on the display Run status is for monitoring purposes only and has no selectable or changeable parameters 6 5 1 Temperature Based Control 6 5 1 1 Preheat Bake Out And PWHT Run Status Screen Run Status Screen Mode P
89. pri s Ne pas augmenter leur puissance ne pas les ponter LE CHAUFFAGE PAR INDUCTION peut provoquer des br lures e Des pi ces ou de l quipement chaud peuvent provoquer des blessures e Ne pas toucher ou manipuler la t te l enroulement induction pen dant le fonctionnement Ne pas toucher des parties chaudes mains nues Laisser refroidir les composants ou quipements avant de les mani puler e Tenir les bijoux et autres objets personnels en m tal loign s de la t te de l enroulement pendant le fonctionnement 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APPAREIL peut blesser e Utiliser la poign e et demander une personne ayant la force physique n cessaire pour soule ver l appareil e D placer l appareil l aide d un chariot ou d un engin similaire e Pour les appareils sans poign e utiliser un quipement d une ca pacit appropri e pour soulever l appareil En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du cote oppos de l appareil DES PIECES DE METAL ou DES SA LETES peuvent provoquer des bles sures dans les yeux e Porter des lunettes de s curit coques lat ra les ou un cran facial DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e
90. r required when ordering parts from your local distributor OM 222 166 Page 54 F Hardware is common and not available unless listed 4 3 NG 804 223 A Figure 11 6 Capacitor Assembly Item Dia Par No Mkgs No Description Quantity Figure 11 6 Capacitor Assembly 1 C3 C6 218685 CAPACITOR popyp met film 1 5 uf 700 VAC 4 8202 guste hiya 218 688 BUS BAR tank 2 rec Res 1221 419 SCREW M8 1 2 x 12 soc hd zinc cls 40 NEE 602 211 WASHER lock 318 ID X 0 586 OD X 078T STL PLD SPLIT 312 40 Recommended Spare Parts t Torque screws to 50 in Ibs 5 6 Nm 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 222 166 Page 55 IS Hardware is common and not available unless listed 804 224 E Figure 11 7 Right Windtunnel Item Dia Par No Mkgs No Description Quantity Figure 11 7 Right Windtunnel E eniro 216 630 WINDTUNNEL RH 222222000000 e n 1 RELA aa ae Da 213 873 HEAT SINK current source 1 cu DEE 213 871 GROMMET rbr sil 8 000 ID x 3 250 mtg hole 2 Na AA 170 647 BUSHING snap in nyl 1 312 ID x 1 500 mtg hole 1
91. rease button will acknowledge the limit and continue operation with the existing set up In the acknowledge state the yellow Limit LED will stop flashing and remain on continuously The LCD display will revert to an active screen once the Program O O kw y button or Parameters EVA button is pressed Z 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 button Run Status O condition press the Run Status button and the LCD display will show a message describing the new and previous limit messages O 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 O O tion press the Stop button After changes are made to the setup press the Run button to restart the process 9 3 Limit Condition Codes Limit Condition Additional Information L01 Thermocouple 1 Open Check for open temperature sensor and repair Change to back up temperature sensor L02 Themocouple 2 Open Check for open temperature sensor and repair Change to back up temperature sensor L03 Thermocouple 3 Open Check
92. reen 18 4 x 40 LCD Display Displays programming runs status pa rameter fault and limit conditions and trou bleshooting guide 19 Thermocouple Input Receptacles Use receptacles for type K thermocouple inputs OM 222 166 Page 23 SECTION 6 SETUP AND OPERATION 6 1 Safety Equipment ra K Wear the following during 4 1 2 operation y Dry Insulating Gloves 2 Safety Glasses With Side Shields DO NOT wear rings or watches during operation Sb3 1 1 94 6 2 System Description The ProHeat 35 Induction Heating Power Source is designed to function either as an air cooled system or a liquid cooled system Depending on the System type either air cooled or liquid cooled the power source is automatically configured to operate and provide an output appropriate for the type of connected heating device A special identifier embedded within the extension cable connector provides the means for the power source to configure itself by recognizing the type of extension cable s attached to its output connectors Designed to provide a single level of output up to 35 kW the ProHeat 35 power source has two panel mounted connectors that are connected in parallelto the power source output This design allows the system to operate with either a single output extension cable or two output extension cables If a single output extension cable is used a protective plug provided with the syst
93. reheat TC5 77 Target Temp TC6 77 Countdown Status Stopped Mode displays the programming mode Preheat Bake Out PWHT or Custom Program During active operation Target Temp shows the target temperature based on the specific program Countdown shows the time remaining in a soak segment and Status shows the program segment type step soak ramp hold or stopped TC5 and TC6 display the temperature of thermocouples 5 and 6 This screen is for monitoring purposes only 6 5 1 2 Custom Program Run Status Screen Mode Custom Program TC5 77 Target Temp TC6 77 Countdown Segment 1 Status Stopped During active operation Target Temp shows the target temperature based on the active segment Countdown shows the time remaining in a soak segment and Status shows the program segment type step soak ramp hold or stopped of the active segment and the active segment number TC5 and TC6 display the temperature of thermocouples 5 and 6 This screen is for monitoring purposes only OM 222 166 Page 33 6 5 2 Manual Control Run Status Screen Mode Manual TC5 77 Power 0 0 KW TC6 77 Countdown Status Stopped During active operation Power shows the actual power delivered from the power source Countdown shows the time remaining in the heating cycle and Status indicates if the system is running or st
94. s travailler seul LES FUM ES ET LES GAZ peuvent 2 tre dangereux Le chauffage induction de certains mat riaux e Couper l alimentation d entr e avant d installer l appareil ou d effec adh sifs et flux g n re des fum es et des gaz Leur tuer l entretien Verrouiller ou tiqueter la sortie d alimentation selon inhalation peut tre dangereuse pour votre sant la norme OSHA 29 CFR 1910 147 se reporter aux Principales nor e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces mes de s curit vapeurs e Nvutiliser que des tuyaux de refroidissement non conducteurs ayant une longueur minimale de 457 mm pour garantir l isolation OM 222 166 Page 4 l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz Si la ventilation est m diocre porter un respirateur anti vapeurs ap prouv Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les adh sifs les flux les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz provenant du chauffage peuvent d placer l air abaisser le niveau d oxygene et provoquer des l sions ou des accidents mortels
95. sques potentiels Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes 4 Disposer le c ble de sortie d un c t distance de l op rateur 5 Ne pas enrouler ou draper le c ble lectrique autour du corps 6 Placer la source de courant et le c ble le plus loin possible de l op rateur En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induction Si le m decin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS 3 1 Warning Label Definitions Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from wiring can kill 1 1 Wear dry insulating gloves Do not wear wet or damaged gloves 1 2 Disconnect input plug or power before working on machine 2 Induction heating can cause injury or burns from hot items such as rings watches or parts 2 1 Do not wear metal jewelry and er other metal personal items such as rings and watches 2 2 during operation 2 2 Do not touch hot parts or hot head coil 3 Induction heating sparks can cause fire Do not overheat parts and adhesives 3 1 Keep flammables away from heating operation Do not heat near flammables 3 2 Heating sparks can
96. stem set up parameters will apply to all programs OM 222 166 Page 25 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 O O the display lights press and hold the Increase and Decrease buttons A message will display Press Program to reset factory O O defaults Release the Increase and Decrease buttons and press the Program 6 4 Programming Programming allows the operator to setup a program for a particular heating process The selections available are either Temperature control or Manual control 6 4 1 Temperature Based Control Temperature basedcontrol operates the system and controls the heating process based on temperature feedback from thermocouple inputs Ther mocouples must be used for this mode of operation or the system will not operate Within the temperature based mode there are four different processes available as follows Preheat Bakeout PWHT Post Weld Heat Treat and Custom Program Press the Program button to access the programming mode Use the cursor button to move the cursor to the desired temperature based process then press the Program button again to select the process 6 4 1 1 Preheat The preheat process is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time When this process is selected the following screen will appear on the LCD disp
97. the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in s the U S A to be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol AA 1 1 2 Induction Heating Hazards 1 1 3 Additional Symbols for Installation Operation and Maintenance 2 1 4 California Proposition 65 Warnings sses sssse ress n nerra renr n renarna 2 1 5 Principal Safety Standards eee ure nr aan STET A RRT RS EER AH 5 0 3 1 6 EMF Information i e enr qr a da ROLE Re 3 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 4 2 1 Signification des symboles 4 2 2 Dangers relatifs au
98. tional Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid rations relatives au chauffage induction et aux effets des champs lectriques et magn tiques basse fr quence Le texte suivant est extrait des conclusions g n rales D partement du Congres U S Office of Technology Assessment Effets biologiques des champs magn tiques et lectriques basse fr quence Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 on dispose maintenant d importantes d couvertes scientifiques reposant sur des exp riences effectu es dans le domaine cellulaire et des tudes r alis es sur des animaux et des personnes qui d montrent clairement que des champs magn tiques basse fr quence peuvent avoir une interaction et produire des changements dans les syst mes biologiques Alors que la plus grande partie de cet ouvrage est d une tr s grande qualit les r sultats sont complexes La compr hension scienti fique courante ne nous permet pas encore d interpr ter la preuve fournie dans un seul ouvrage coh rent Il est encore pl
99. us frustrant de ne pas pouvoir tirer des conclusions d finitives en ce qui concerne les probl mes de risque possible ou de proposer des recommandations scientifiques OM 222 166 Page 6 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org et www sparky org Code lectrique du Canada partie 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Mississauga Ontario Ca nada LAW 5NS t l phone 800 463 6727 ou en Toronto416 747 4044 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 25 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org claires pour des strat gies suivre en vue de minimiser ou de pr venir des ri
100. ut Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source grounding terminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line terminals Close and secure access door on welding power source Disconnect Device Input Power Connections 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 9 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals Tools Needed 10 Over Current Protection Select type and size of over current CIRO 3 8 in protection using Section 4 4 fused dis connect switch shown EY Close and secure door on line disconnect 803 994 C device Remove lockout tagout device and place switch in the On position OM 222 166 Page 13 4 6 Connecting 3 Phase Input Power For 400 460 Volt Models Tools Needed C FI 83 8 in
101. xtinguisher nearby e Keep flammables away from work area e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e Do not operate where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e After completion of work inspect area to ensure it is free of sparks glowing embers and flames e Use only correct fuses or circuit breakers Do not oversize or by pass them INDUCTION HEATING can cause burns e Hot parts and equipment can injure e Do not touch or handle induction head coil during operation e Do not touch hot parts bare handed Allow cooling period before handling parts or equipment e Keep metal jewelry and other metal personal items away from head coil during operation 1 3 Additional Symbols for Installation Operation and Maintenance FALLING UNIT can cause injury e Use handle and have person of adequate physical strength lift unit e Move unit with hand cart or similar device For units without a handle use equipment of adequate capacity to lift unit e When using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit a Ng FLYING METAL OR DIRT can injure eyes e Wear approved safety glasses with side shields or wear face shield MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and s

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