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Miller Electric IH User's Manual

1. oO Front Connect the power output cable and coolant lines as shown Connect 110 volt power cable as shown Plug the 110 volt cooler power cord into the duplex at the rear of the power source cart On the 25kW system the cooler must be plugged into the right side duplex This is identified with a label that reads switched receptacle The ON OFF switch located to the left operates this OM 203 185 Page 10 o RE Hose From Cooler mi Power Source 14 Pin Control Cable Output Connectors 26 a Oo Yellow 110 Volt From Hose From Cooler IH TS To Cooler plug The IH TS Control is plugged in the left side duplex Do not use these duplex connections for operating auxiliary tools such as grinders drills lights etc Connect output power cables to the output connectors All coolant connections have 5 8 18 left hand threads JE Yellow A Red Hose From Power Source To IH TS 110 Volt From IH TS 803 036 Connect the coolant out line from the cooler directly to the output ex tension cable Connect the coolant in line on the IH TS directly to the remaining output extension cable connection Connect the coolant out line from the IH TS to the coolant in line on the cooler 5 Cooler Connect the power output cable and
2. 21 6 3 3 Batch Recording Using 5100 Digital 26 06 920 T LOGIN AS USO a d be ada qd ia 26 6 3 3 2 olall RECOMING scar peer te Hee e RSV eM MOM eM 26 6 353 3 s eic xor RR DER ee Cg Ce LA ROS S CRUCE RU an UE 27 6 3 3 4 Saving Data To A Disk Recommended After Each Batch 27 6 3 3 5 Saving Data To A PC Alternative To Floppy Disk 27 6 3 3 5 1 Review Software First Time Setup 27 6 3 3 5 2 Creating A Shortcut First Time 27 6 3 3 5 3 Changing IP Address To Connect The 5 28 6 3 3 5 4 Downloading Files From 28 6 3 3 5 5 Troubleshooting Connection Problems 29 6 3 3 5 6 Resetting IP Address Necessary To Connect User s PC To Company s Network 29 6 3 4 Running A Program To Preheat Or Stress 30 TABLE OF CONTENTS 6 3 5 Recovering From An Interruption 31 6 3 6 Viewing Data In Review Software
3. Oe gen du 52 8 3 Diagnostic Procedures For IH TS Cy x XY RE 55 8 4 Resetting All RAM Variables In The Event Of Display Errors 58 9 5 Facto Sel Parameters zo ex an TRE PCM 59 8 5 1 Controller Version 59 8 5 2 2408 Controller Edit Parameters 4 60 8 5 3 2408 Controller Full Parameters Prior To Version 4 09 61 8 5 4 2408 Controller Configure Parameters Prior To Version V4 09 62 8 5 5 2408 Controller Full Parameters Effective w Version 4 09 63 8 5 6 2408 Controller Configure Parameters Effective w Version 4 09 64 8 6 Calibration Certification Procedure 1 65 SECTION 9 ELECTRICAL DIAGRAMS Si su very eva ES X a YE one Rh n rm on me s 66 SECTION IO PARIS LIST cuis ee ox A mons 67 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this p
4. DR Ed 3 SECTION 2 MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION 4 2 1 Dangers suppl mentaires de mise en route de fonctionnement et d entretien 5 2 2 Informations concernant les champs lectro magn tiques Information EMF 6 2 3 PRINCIPALES NORMES DE S CURIT 6 SECTIONS INTRODUCTION rito 9093 00a at ROI c Rc Dacus aba REO eux 7 SECTION 4 INSTAELATION 2 ne demon 8 SD CIICAIONS Dead eee MEET ae 8 SEC NN IAES GS rm 8 4 3 Gonnectinig TO POWOF SOUTE 13x me sk wae dO aC COP XO Ce CC e CD oaa de Ve ie aetas eee 9 4 4 Input 14 Pin Information For Receptacle 1 9 4 5 Connecting 25kW System Cords And Cables 10 4 6 Connecting 5kW System Cords And Cables 11 4 7 Connecting External Device e RR ER lol erae RR C dct e tl e ON t gd a Ra n t 12 SECTION 5 COMPONENTS AND 5 13 5 1 Ip RO Rane OEC COD CERE fe E te EE 13 32 Piel or sro deus Sivan dfe prae Rant 14 COMMON Cl ages C Pr EE 15 SECTION 6 SETUP AND OPE
5. Ne pas surchauffer les composants les adh sifs Attention aux risques d incendie tenir un extincteur proximit Stocker des produits inflammables hors de la zone de travail 203 185 Page 4 Installer et mettre cet quipement correctement la terre conform ment au manuel utilisateur et aux codes nationaux gouvernementaux et locaux V rifier souvent la terre de l alimentation contr ler et s assurer que le conducteur de terre du c ble d alimentation est correctement reli la borne de terre dans le boitier de d connexion ou que le connecteur est branch une sortie de boitier correctement mise la terre En r alisant des connexions d entr e brancher d abord le conducteur de terre appropri contr ler deux fois les connexions V rifier souvent le bon tat du c ble d alimentation ou l isolation des fils remplacer le c ble imm diatement s il est endommag des fils d nud s peuvent provoquer des accidents mortels Arr ter tous les quipements lorsqu ils ne sont pas utilis s Ne pas utiliser des c bles us s endommag s sous dimensionn s ou mal piss s Ne pas porter les c bles autour de votre corps Ne pas toucher le circuit lectrique si vous tes en contact avec la pi ce la terre ou le circuit lectrique d une autre machine Utiliser seulement des quipements bien entretenus R parer ou remplacer imm diatement des composants endommag s Effectu
6. The values at the cursor location appear on the right side of the screen 5 1 1307 Rec Id 244 stap Eng p Id 244 5 These steps must be done sequence for Batch information to display properly Job Operator 2458 2 OF 2 OF 2 OF 2 18 13 1 2 15 2 15 EE 02 15 02 02 48 00 02 15 02 10 56 00 NUM Start MILLER Applications for P Full View bmp Paint Review Chart2 3 scrn18 z Chart properties may be edited by ae Review Chart1 selecting Chart then Setup gl scrn19 OM 203 185 Page 41 Chart Setup Point Properties OM 203 185 Page 42 ANIM amp MINZ ANIN amp MINA wW4 1307 2 5 wW4 1307 2 5 wW4 1307 2 5 wW 1307 2 5 t E To remove TC click on the Point ID then click Delete Point To edit a TC trace properties select a TC Point ID then click Point Properties Select to return to the chart scrn20 Span dictates the range of tem perature to plot for the trace Interpolation On will show a smoothed line between points instead of steps Interpolation adds an I to end of descriptor Select when done scrn21 Comments can be added to the w Review
7. 32 6 3 6 1 Installing Review Software And First Time Setup 32 6 3 6 2 Backing Up The Database s 4 02 ee RE TREE ERR IT ENS 32 6 3 7 Running Review Software 33 6 3 6 Typical Pronie CharbPrntoll 2220220053 xx rev ERE Gm RR ox eder Ron ee o E00 ews 47 SECTION 7 CONFIGURING CONTROLLER AND RECORDER 48 7 1 Changing Controller Operating Window Ramp Dwell Or Temperature Units 48 7 2 Changing 5100V Recorder From Degrees F to Degrees And Change TC Descriptor 49 7 3 Restoring Recorder Configuration From A Floppy Disk For 5100 Digital Recorder se de arse gt Dro e n oce te Qupd dece ae 50 7 91 Load File acinis Aine donus das cales Bae oet e ded pe ca te Mene dod e 50 2 Dale tice conte anual ann ee pe dere Cla d du ee 50 459 9 Taie OO ccr do are AO cU eate ae ci epe rre obw oe ee ee d nod D CER A 51 7 9 4 LOGIVAS USOT us soo hc bote c Co De Sube Bold acus 51 Too Home SCEE rU 51 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 52 Fouine Malltenariee zou e Dukes x hae Aene Rates Aces et 52 9 2 ILroUblesnoollig isdem
8. al Et s Oo cg C C3 LL E3 LL Oo uu c 25 CL co D TD 5 2 b d LI ha 5 a O L1 Lu LO 1 N 5 pe O 9 D O LA V E 5 2 D xc e bad LL u co en C Cr J 2 6 eu ea 2 Lo 0 LL I J c3 a h o EE LL Lu O O CC g OO 7143 t LL zZ o E LL ul uu r C a Oo Lo c DE LL ml lu un nu rm gu 5 C CL ck En 3 Pow wel Lac lt 0 cf 8 CC 00 Sog Ore TN Lu 3r 0986 jas m a 5 wd 111 uL ot lt SC wm OD 828 Es m a 57 J50 1 ld LL O SO laul h ual Sc ctl cc a 3 un E Oo Alarms Config AL LanF Ld Hi LEch nno nno HL 2 Brun Eo PU u mal u Lu La bh 4 d oO oO 5 n gc 5 oO a e LL L lc oc C aly LL Eb pe au t5 Qoo Mi c C3 L E Lu a a 25 h E E H c G J O LI Ly CC _c ep
9. 203 185 2005 09 I er Processes Induction Heating Description Single Induction Heating Power Source Temperature Control Recorder OWNER S MANUAL File Induction Heating Visit our website at 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 Ir BL El Her This Owner s Manual 15 designed to help you get the most out of your Miller products Please take time to read the Safety precautions They boleu Ie ete jue ex e every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick Late and easy With Miller you can count on years MI 0001 2000 of reliable service with proper maintenance And if for so
10. se Esl B SR 26 RE u cB EE uL T wal T mal fe T Fal Le T Cr S o TE ue Fe a bh La bh NEUE 500 o D 3 D 3 D 3 n un SE LL L c Lu c gu Lu w Hu oo M Lo EQ c3 Lo L E Lu T c p H c H 3 O L4 Lo CE D n Le co S Fu fu e a3 50 a gt Pry 3 0 L E gt 5 au LL cc cc Aug Lu Iz TC fel RU BE Du Be wm PELL Foe Lo foc ee etl Gs PU m tz rz Mel Js Zau foo fas jou Fu Lo fio ES Navigation Page Across Scroll Do OM 203 185 Page 64 8 6 Calibration Certification Procedure The following items are required for verifying calibration 1 Fluke 714 Thermocouple Calibrator this be obtained from http www fluke com products home asp SID z13 amp AGID z9 amp PID 1707 specify primary standard certification when ordering 2 Type K Mini Connector Fluke 8 Or Equivalent this can be obtained from http thermo electric direct com control interliant com Miniature Quick Coupling Thermocouple Connectors10630 html 3 Type K 2 Pin Male Connector this can be obt
11. would consist of Miler 60098420000007 50 uhh Miller 41 1321 1 5 7600 Group Descriptor Time Date stamp uhh Miller 8010984 2000000152 uhh ee ae Med du The file creation time can be found using 8009842000000157 uhh the Detail Button Miller w41 1308 2 5 780038A20000060153 uhh Select the desired file Mille 41 1308 2 S 8009885 2000000154 uhh Select Open Filename Miler 80098420000001 4E uhh Files of type Packed Archive Files Cancel Transter File name A histon Mille 20000001 4E uhh Log group Miiller Log start time 02 1502 07 05 51 625 Enter the Job Batch Name in Select or Enter Instrument tag Ed the field next to Select or Enter Instrument tag Enter Batch Name if required Mille This is the File name the mE information will be stored in If a batch was not started enter the Lancel Job Batch Name in the field next to Enter Batch Name if Required as well Select Start Transfer Proceed to New Instrument E pop up window top of page 37 203 185 Page 36 Multiple Files With Batch Names Select archive data to transfer to database Look in history Miller S0038420000001 4E uhh Miller 80095420000007 50 uhh Miller S0038420000001 52 uhh Miller 5003840000001 57 uhh Miller w41 1302 2 5800954 Mille w41 1307 2 57600984 20000001 54 uhh Miler w4t 1307 2 S 80098A2000000153 u Files of type Packed Archive Fies Cance
12. 6 3 6 Viewing Data In Review Software 6 3 6 1 Installing Review Software And First Time Setup Insert the Chessell 5000 Series Data Management System CD into the computer If the installation program does not automatically start browse to the CD using My Computer and run Setup exe Place a check in the box next to Review The other components are optional Additional information about the software can be found in the readme txt file on the CD Click Install Recorders Software and accept the default settings of the software installation This Owner s Manual will guide you through the steps to create and save a chart for a batch file Additional informa tion on the Review software is available under Start Programs Eurotherm Manuals Review Manual The first time Review software is launched a message box will be displayed to enable Review Full features Place a check in the box for Don t ask me this again then click Review software first time setup Screen vau want to temporarily enable Review Full features Don t ask me this again may be reactivated from Options menu scrn35 6 3 6 2 Backing Up The Database When Review software is used archive data is stored in a database on the PC As files are transferred to the data base the Review erv file size increases Data transferred into the database can be deleted but not moved If the Heview erv file size reaches 1 gigabyte data will n
13. Q3 to change the operating Window units gt to change Ramp units rmP L Hour n or SEc Hour to change Dwell units dwt Ex E Wait 2 seconds Haur m n or 5Ec Haur WES Controller resets 5 n LAN mun uM 150 Imm lt 1 temp lt Setpoint Sm M eR 203 185 48 7 2 Changing 5100V Recorder From Degrees F to Degrees And Change TC Descriptor Log in as Engineer see Section Save Restore Config Security Network system 1L 1 Press Menu bottom right of Select Config Channels Select Channels from pull down menu Groups Views Events Instrument Archive Batch scrn32 For each Channel Number 1 6 Save Restore config Security Network system 4 Select Channel Number Channel Number 1 TC 1 Y temperature range reading 1500 for typ Input Type Thermocouple Y 1472 F 5 for C yp Lin Type Type Y Range units be changed between and Range Low 0 F 4 Descriptor can be changed in Range High 1500 o o F Descriptor field if desired Range Units Press Apply Scaled Offseti0 F Filter 2 Seconds Y Break Response None v Cold Junction Type Internal Descriptor TC 1 7 Spanned Zone Low 0 Zone High 100 Max Decimal Digit
14. Wear following during operation 1 Dry Insulating Gloves 2 Safety Glasses With Side Shields DO NOT wear rings or watches during operation sb3 1 1 94 6 2 IH TS Setup 6 2 1 Select Power Source Energize the power source cooler and IH TS A power source selection will appear in the top right corner of the IH TS front panel Parameter Display Press the recessed Power Source Select button on the IH TS rear panel to toggle through and select the appropriate power source maximum output This selection will provide the proper out put scaling in the parameter display screen for the power source that is attached to the IH TS Parameter Display Power Source Max Output KWPwr PS 2541 j Amps rms Volts rms KHs Frequency OM 203 185 Page 16 6 2 2 Time Date Setup Digital 6 2 2 1 Digital Recorder Controls Keep all panels doors and covers closed and secure during programming Up Page Down Left Right Option 6 Menu Additional keys that appear as needed for specific applications are as follows 7 Close Folder 8 Open Folder 9 Left Cursor 10 Right Cursor 6 2 2 2 Login As Engineer 1 Touch top left corner Logged Out or User Touch Blue text pull down menu next to User Touch Engineer Touch Password field 2 3 4 5 Touch Numeric 6 Touch 1 then 0 and finally Ok Engineer will appear in top left corner of display 6 2 2 3 Go To Op
15. 0 n LL cl co gt a u c ho Eu 029 c3 gt LA O C O DL ui CC oc YU uy L 4 ui c HI L Hu ao ua eG Gal El es LE fee Ju 8 Q Z fo fo 5 Ww 0 Lu n LL fio Navigation Page Across e Scroll OM 203 185 Page 62 8 5 5 oko FuLL Navigation Page Across Scroll Dow 2408 Controller Full Parameters Effective w Version V4 09 9 S g 5 L D Un I 2 c 5 Qj D E o o o o RS Bol 5 i e e as a s a s s an w e 9 L4 gt jo gt bo gt fo gt j ls L E TD 6 e LO 2 T LB CL 1 Sug EB EE ES LA PH BS E 8 3l 6 V 9 RN 5 au H au PE a CZ M gt E uj La cal X cI L zn Sup 28 Ee Re Be Eu BE 22 a ni a a E T mE 55 Bel Gel Bal ES 85 1 E 3 c UCI Ladc aU Lm L Lac 30 EB LI 3 49 Lu LE FE 1 pr D a m E uj a L Cj LU Sa
16. 00000000 000000 mn me cm a a Tools Needed 4J C 3 8 5 16 Ref 802 905 A 802 900 OM 203 185 Page 8 4 3 Connecting To Power Source Turn Off power source 1 IH TS 2 nterconnecting Cord 3 14 Socket Plug 4 14 Pin Plug Obtain cord with 14 socket plug on one end and 14 pin plug on other end 5 Keyway 6 Remote 14 Receptacle RC1 See Section 4 4 To connect cord to a receptacle align keyway insert plug and tighten threaded collar To connect remaining end of cord to power source align keyway insert plug and tighten threaded collar sb7 1 3 93 Ref S 0004 A S 0750 Ref 802 926 Ref 801 049 801 825 B Ref 803 004 A 4 4 Input 14 Pin Information For Receptacle RC1 A REMOTE 14 Pin Pin Information A 24 volts dc from power source Remote Contactor B Contact closure to A completes power source 24 volts dc contactor control circuit D Control circuit common Remote Output Control E to 10 volts dc signal for power source output control Power Source Fault F J Absence of contact closure from power source indicates power source output failure Actual frequency input signal Average power input signal Remote Metering Voltage input signal RMS 2 Current input signal RMS See power source Owner s Manual for scaling information OM 203 185 Page 9 4 5 Connecting 25kW System Cords And Cables
17. 14 088731 BUSHING snap in nyl 1 PT 15 42245 333 SWITCH pome no SPST TA 115 VAC 2324 x DR Leste eie ceat e o x e hes E 2222209 0995 BD eh en alae acte ne an Me seseg 147 8760 a ABEE WOO DM pp eee ees ean I oos een 16 222461094029 WRAPPER aoreet ceci oe rec eco etai 71 19 sd odo STANDOFF x dunt Re ee d ote 00 MT 20 115094 HOUSING PLUG amp SKTS o rea Te us os a Go ee vex 1 Cm 21 158506 SWITCH rocker 10A 250VAC 1 OM 203 185 Page 67 Mkgs Description Quantity Figure 10 1 Complete Assembly Continued iue 22 24669 198 893 RECEPTACLE thermocoUple tbe v ADD 23 209948 BRACKET mtg receptacle RJ45 2 24 175282 COVER receptacle weatherproof duplex rcpt 1 25 203 975 c CAPACITORASSY xac dod os ende reso dete ate dac Mte iet E 26 198 885 CABLE interconnecting s c cr ERI Re ez re 1 E 204102 s GORE TOOGA tintin nee 2 Deere DO 1 525204 aa CORE toroidal 22 cece iren e Es sde bie ess ott 29 203264 NA
18. Setup OM 203 185 Page 38 New instrument is displayed Select OK to add the Instrument tag scrn11 Select File Select New Chart scrn12 Select Add Point scrn13 Select Point wW41 1307 1 5 E AME wW41 1307 3 5 wW41 1307 4 5 w41 1321 1 5 amp MINT ANIM 2 ANIM 4 amp MINE MINT ANIN2 AMIN amp MIME Select Instrument this is the Instrumenttag Job Batch Name that was entered previously scrn14 Select the appropriate Log Group Select Point ID to add a specific point then select OK or Select Add scrn15 OM 203 185 Page 39 Chart setup Sl E E S EE OM 203 185 Page 40 ANIM amp MINZ ANIN amp MINA w4 1307 2 5 wW4 1307 2 5 w4 1307 2 5 wW 1307 2 5 Change Grid Major divisions to 30 resulting in 50 increments from 0 1500 F Select OK to view chart scrn16 This display is the default view of the profile Note the values show No data which is due to the dashed line on the right side of the screen being outside of the data values scrn17 a Drag the slider on the left down to E3 Ele Edt View Instrument Chart Options Window 18 zoom the view out EE ce al 55 Click the maximize box to enlarge to full screen Click on the profile the dashed line moves to the cursor location
19. and operating the recorder OM 203 185 Page 7 SECTION 4 INSTALLATION 4 1 Specifications Specification Description Overall Dimensions Height 10 in 254 mm Width 14 1 2 in 368 mm Depth 16 in 406 mm Weight Net IH TS no recorder 13 1 Ib 5 9 kg IH TS digital recorder 21 1 Ib 9 6 kg Type Of Input Power 24 Volts DC 115 Volts AC Memory Capacity One Program Up To 8 Segments Control Capacity Single Power Source Control Operating Temperature Range 41 To 104 F 5 To 40 C Storage Temperature Range 4 To 122 F 20 To 50 C Reference the controller and recorder manuals for additional information 4 2 IH TS Installation Turn Off and disconnect input power 5 kW System 1 Temperature Control Recorder 2 5kW Mounting Bracket 3 Screw 10 32 4 Install and secure IH TS to mount ing bracket using supplied 10 screws 4 5kW Power Source Case 5 Case Sheet Metal Screw 4 Remove case sheet metal screws from both top left and right sides of unit Install mounting bracket to power source and secure by rein stalling sheet metal screws 25 kW System 6 25 kW Power Source Case 7 Rear Mounting Bracket 8 Screw 1 4 20 2 Remove front and middle mounting screws from top of Item 6 case Lo cate IH TS and reinstall front mounting screws Locate rear mounting bracket and secure with supplied 1 4 20 screws Reinstall middle mounting screws to secure bracket to case
20. coolant lines as shown Connect 110 volt power cable as shown Plug the 110 volt cooler power cord into the duplex at the rear of the power source cart 4 6 Connecting 5kW System Cords And Cables Hose From Cooler To Output Extension Cable The IH TS Control is plugged in the left side duplex Do not use these duplex connections for operating auxiliary tools such as grinders drills lights etc e Connect the coolant out line from the cooler directly to the output ex tension cable Output Connectors Hose From Output Extension Cable To IH TS 803 040 A Connect the coolant in line on the IH TS directly to the remaining output extension cable connection Connect the coolant out line from the IH TS to the coolant in line on the cooler OM 203 185 Page 11 4 7 Connecting External Device The IH TS must have as a minimum 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 control proceed as follows Turn Off power source 1 Temperature Controller 2 Thermocouple Receptacles 3 Individual Thermocouple Plug 4 Thermocouple Extension Cable of 6 Align plug pins with receptacle ey a 5 sockets and push plug into TRH C receptacle T gt 5 Coolant Line From Coil 6 Line To Cooler Coolant In Port 5 is s
21. gt 85 lt 2 x jCc3 Fa Ty cl fo cul in REL 9 14 3 uL C C L PT Le 33 u Et QO 1 uL Home Run List List 14 run 00 Li SE OF OFF 1 E varies na m H d Auto WES OM 203 185 Page 63 8 5 6 2408 Controller Configure Parameters Effective w Version V4 09 9 Ae 5 i 8 D O S gt c D LaL LL CL G un kil Lt oO DL Lj Lu Oo 5 amp 9 wj d Iaj j a i c al ral Fee g Oo 11 0 C C3 LL LL Cj G OQ du D co 5 5 5 LL LI LU oc C O Saj fea O L1 Lu lO Aj 29 5 LL Lu LI Lu oc C Q al una m O pi C 9 o fe Tg ju p Fe C 1 col 1 J c 2 Pu ee ea d 2 t3 n Lo 0 LL I J c3 c3 h o ED LL Lu oo S a a 30 OO 1 LL o E LL ul r C a Oo Lo c DE LL u SSS ES pal SS L o 290 cf n 9j _ 00 T L3 Ln eoo n amp fot u uL ot Cwm eas L el Lal le sal 37 J Lj u S LI an
22. les nettoyants et les d graisseurs LA DE MATERIEL peut provoquer des blessures personnelles graves et en dommager les quipements 1 Utiliser la poign e et demander une personne ayant la force physique n cessaire pour soulever l appareil D placer l appareil l aide d un charriot ou d un engin similaire Pour les appareils sans poign e utiliser un quipe ment d une capacit appropri e pour soulever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil LA PROJECTION DE PIECES DE METAL ou DE COLLE peut provoquer des blessures aux yeux 1 Porter des lunettes de protection avec des protec tions lat rales DES ORGANES MOBILES provoquer des blessures peuvent 1 S abstenir de toucher des organes mobiles tels que des ventilateurs 2 Maintenir ferm s et fixement en place les portes pan neaux recouvrements et dispositifs de protection DES CHAMPS MAGNETIQUES CREES PAR DES COURANTS ELEVES peuvent affecter le fonctionnement du stimulateur cardiaque 1 Porteurs de stimulateur cardiaque restez distance 2 Les porteurs d un stimulateur cardiaque doivent d a bord consulter leur m decin avant de s approcher des op rations de chauffage induction Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur Demander toujo
23. 1350 to 600 Free fall to as fast as 600 hr F for 1 2 hour 600 hr ambient possible SEL n SEL rua un Liu 2 un C1 EL un DEEP rmP r dwE rmP r End step ramp rate soak ramp rate end ELE ELE dur ELE End 1350 18 5 BP deg deg in hrs deg sets output to O AEE 7 mu AR riri HE deg hr deg hr Example Stress Relief Profile 1400 1200 1000 0 Co eo Degrees F e eo i 3 0 30 60 90 120 150 180 210 240 270 Time minutes small diameter pipe it may be necessary to reduce the output of the power source to achieve a reasonable rate in Segment 1 thereafter the program controls the rate of temperature rise and the output power may be increased to full if desired To reduce output power turn power source output knob to desired setting Figure 6 2 Setting Stress Relief Profile Using Example Parameters OM 203 185 Page 23 Step to 600 F as Ramp to 800 F Ramp to 1250 F Dwell 1250 F Ramp to 800 F Ramp to 600 F Free fall to fast as 400 hr 200 hr for 1 hour 200 hr 400 hr ambient possible un C1 C7 CA ms CA LI CA 5 Ln cq x ru DEEP rmP r rmP r dwE rmP r rmP r End ste
24. 15 16 17 Touch No Batch In Progress Touch New Touch field next to Job Batch Name This will be the batch name Enter unique Batch Name see Section 6 3 3 Touch Touch field next to User ID Enter User ID Touch Ok Touch field next to Comments Enter Comments or at least touch the blank key Touch ocroll down to bottom of screen Touch field next to Rec ID Touch the blank key bottom right keyboard Touch Touch Start Touch Close OM 203 185 Page 26 6 3 3 3 Stop Recording 1 Touch the block with the batch name 2 Touch Stop 3 Touch Close screen returns to the home screen and displays No Batch In Progress If a batch file was not started the temperature data is still recorded The Job Batch Name User Comments and Recorder ID are not recorded 6 3 3 4 Saving Data To A Disk Recommended After Each Batch 1 Insert floppy disk into recorder 2 Login as User see Section 6 3 3 1 3 Touch key in bottom right corner to open Root Menu 4 Touch Operator 5 Touch Archive 6 Touch Disk 7 Select how much data to save to floppy typically Last Day is sufficient Last day saves from 12 00am until current time Last week saves from 12 00am Monday until current time Scroll down and wait until archive transfer changes from active to inactive NOTE DO NOT remove floppy disk before completio
25. 15 volts ac is not present check wiring C 5100V Recorder Does Not Turn On But 2408 Temperature Controller Does Turn On Place IH TS power switch in the Off position Open floppy drive door Place IH TS power switch in the On position Check for floppy drive light illumination If drive light does not illuminate proceed as follows Remove IH TS wrapper OM 203 185 Page 55 Check for 115 volts ac at plug on rear of recorder and reseat plug If 115 volts ac is not present check wiring between plug PLG4 receptacle RC4 and power switch If 115 volts ac is present at plug on rear of recorder check that green LED is illuminated by viewing through louvers on side of recorder A green LED should be visible through the louvers on the side of the recorder If green LED is not illuminated replace recorder If drive does illuminate replace the recorder D Flow Limit Light Does Not Illuminate When Cooler Is Turned Off Check that cooler is plugged into switched receptacle and switch is in the Off position Unplug cooler power cord from receptacle Disconnect power output extension cable from power source Press green Run button and check if Fault Limit light illuminates If light did not illuminate check if power source displays Under Frequency Fault If power source does not display fault consult power source Owner s Manual for troubleshooting If power source does display fault check parameter display for error message If error message a
26. 91 ssoJoy eDeg LI 203 185 60 8 5 3 oko FuLL Access Information List NO Li SE Output Li GE List Input List Li GE Setpoint List PID List D d Li GE Autotune List Li SE Alarm List HL Li SE Programmer List ro Li GE Run List run Li SE Home List 14 00 OF varies Page Across Scroll Dow Navigation 9 L4 gt 4 Cj LL C3 LE 10 UF 3 0 L OP P d Eun dr H idHi 05 T 0 dui L Hour bAnd H GE LaL H varies La L LL Hb C3 400 49 Hdc mHn E DFF df n d 2408 Controller Full Parameters Prior To Version V4 09 varies Louk varies PL 0 PH Ed DFF Dn no na mLE rESL varies Gb LP MSO DFF C3 Lcb Auto b 50 Hebe Auto Refer to Section 8 5 for additional navigation instructions ch uko OM 203 185 Page 61 8 5 4 2408 Controller Configure Parameters Prior To Version 4 09 9 S Q 5 p 8 gt D 5 D La LL o Eg __ LL ca Lt c nu z O DL Lj Lu Oo NS o a S o I LL ad 1 1 cl c
27. Heat On light will be on and power source will not provide output Providing the Panel Remote switch on the power source is in the remote position 2 If the current temperature is more than 25 F above the target temperature in segment 1 the blue Heat On light will be off and the system will not provide power Regardless of Panel Remote switch position To continue from the current part temperature rather than waiting for the part temperature to fall to within 10 of segment 1 s target temperature Press the HOLD button The controller displays HOLD Press Page button until Prob appears on the display Press Scroll button to SEL Ps ELE temperature setting Use A Or Up or Down button to adjust target temp to the current temperature of 5 F Press B Page button until parameter screen appears on the display Press RUN button to resume program the controller will step to the new target temperature setting and continue through the remainder of the profile Keep all panels doors and covers closed and secure during programming 2408 Controller Page Forward Button Scroll Button Run Hold Indicator Down Button Up Button Actual Temperature Setpoint Temperature Heat On Pilot Light Fault Limit Light 11 Run Button 12 Hold Button 13 Stop Button O AUTO RUN Ted MAN HOLD 4 1 2 203 185 31
28. MEPLATE rear w o recorder 1 eatin 29 204 367 NAMEPLATE rear w recorder 1 30 2225102 492 BOPT PINS 1 204227 2 Mtg IHFTS ede rere ad Pe ee So ci eene eo TUMOR 32 204040 MOUNT nprn 100mm recorder 55 durometer 1 UT 33 244 532 CABLE ASSY interconnecting 45 2 34 194067 CASE SECTION 1 T 35 202602 SWITCH flow 05 1 D 06 ties 194 068 2 PANEL IONE orae i t ce rco andes uu II 37 194 920 RECORDER temperature digital 1 rr 38 212719 KIT switch replacement for 203 137 including 1 PUE ee NS 203 137 SWITCH pb mc DPST NC NO 115VAC red 1 7210369 lt 2 BOOT SWICHPUSADUIONT 32 3 mis d tue 39 212718 KIT switch replacement for 203 136 including 1 Tm 203 136 SWITCH pb mc SPST 115VAC black 1 TID 210 369 1 BOOT Switch DUSHDUNON 25 5a bare DT M lek eee 1 40 212 717 KIT s
29. NCE ET DE REPARATION NE DOIVENT ETRE CONFIEES QU A DU PERSONNEL QUALIFIE Danger de mort PAR ELECTROCUTION Le contact de composants lectriques peut provoquer des accidents mortels ou des br lures graves Le circuit de puissance et les connexions de sortie sont sous tension lorsqu on active la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur marche Des quipements install s ou reli s la borne de terre de mani re incorrecte sont dangereux Ne pas toucher des composants lectriques sous tension Envelopper les connexions et raccords de refroidissement pour viter tout contact accidentel Porter des gants d isolation secs sans trous et une protection corporelle Isolez vous de la pi ce et du sol avec des tapis ou des couvertures d isolation suffisamment grands pour pr venir tout contact physique avec la pi ce ou la terre D connecter l alimentation avant d installer l appareil ou d en effectuer l entretien Verrouiller tiqueter la sortie d alimentation selon la norme OSHA 29 1910 147 se reporter aux Principales normes de s curit Utiliser seulement des tuyaux non conducteurs avec une longueur minimale de 460 mm pour assurer l isolement LE CHAUFFAGE PAR INDUCTION peut provoquer des blessures ou des br lures au contact de 5 CHAUDES OU DE L EQUIPEMENT i LE CHAUFFAGE PAR INDUCTION peut
30. OML3N 215 588 A t Diagram For IH TS Ircul Figure 9 1 C OM 203 185 Page 66 SECTION 10 PARTS LIST 43 42 41 Ref 803 005 Figure 10 1 Complete Assembly Dia Part Mkgs NO Description Quantity Figure 10 1 Complete Assembly 1 203262 NAMEPLATE W o recorder 1 RN 1 322122 204 366 NAMEPLATE Wrecorder ch Abreise xS 2 usce 147002 ss CENS clear anti ass Hence 1 PT dovesse 1454416 2 GASKET Meter lens odd CAR Ceo Ch Deest aged 71 AT 420011900909 RUBIO AV SE uasa og e at ih et ed TOES 5 145 209182 xx EOD W IbDDODmOable cum e epa amp ert nee eee 1 TIT 6 204039 MOUNT nprn 1 8 din controller 55 durometer 1 TEE y NER OO Eo CERE CIEGO NERO TT 8 186 162 RELAY 120VAC DPDT 5A 120VAC 2 9 203181 CIRCUIT CARD ASSY pendant control 1 10 164 899 HOUSING PLUG PINS amp SKTS 1 RTT 11 169240 HOUSING PLUG PINS amp SKTS e l EE 12 072253 STUD connection Single 1 E rerba T9 toes 115 090 HOUSING PLUG amp PINS taie d TNNT
31. RATION 16 6 1 Salety 2s caus cede das ba ORA Rb RAUS ee ene eee Eu 16 16 6 2 1 Select SOUICE 45 ex Rs ae D RC Ae D 16 6 2 2 ime Date Sep Digitales RS MR Rd ace 17 6 2 2 1 Digital Recorder Controls xe x dex Xxx RAE Rx EG ie a e ai MA 17 2 2 2 AS Engineer sex udi ane nie te eee ee eee EPI SE ake 17 6 2 2 3 Go To Op rator Screen us duh E D e e o o ME cra e 17 0 2 2 4 Locale SOlUpD ut ida ee dr d ce la 17 6 2 2 5 Time And Date Setup isses lulu dE RS ead 18 p 2 2 6 EogImAS SEL EL Ete EE dam edu Sd ado fades 18 62 27 120 OMG Screens ce eden RE Red fusi x iia ard 18 6 2 2 8 Channel Cycling On Off And Notes 18 Ora Operaio ee rane sepan nes cet 19 6 331 2408 GORBIFOlGI a tes irat a c diea a RO Pe I X EQ ec E P CE ae t 20 6 3 1 1 2408 Controller Operation 20 6 3 2 Programming The 2408
32. Setup Select Batch from pull down menu Select Print Tora 2i scrn30 OM 203 185 Page 46 6 3 8 Typical Profile Chart Printout TC4 CS F TGF NUT Rp losp 150 250 s 440 540 650 750 850 950 1050 1150 1250 1350 pun um sa CETTE TEE EN ET LEE LIN MI e on TUN N 2 Jy Mee ees Im BR S aoe BE WY 8 8 1 20 61 2 SZL 70 11 40 20 91 20 4 UL i 1 i d99 S C L0 L E AT ae p SEL ud P i A d 0 Jo 1307 2 5 d Irt pou A NN L 00 en stress ae 02 15 02 13 13 18 500 Rec Id 2442 E E 10 692 12 9v L 20 51 20 203 185 47 SECTION 7 CONFIGURING CONTROLLER AND RECORDER 7 1 Changing Controller Operating Window Ramp Dwell Or Temperature Units Use the following instructions if changes are required to Operating Window Ramp Dwell or Temperature units D D m Des E un DO ms Lam CY cone CY e Pali to Loto Full 0 LonF war Conk Li GE c 2 Sec PAGG B to Hb bAnd LanF gt to change the operating Temperature units to A or Er E3C
33. W41 1307 2 5 CGP chart by selecting Annotate from Chart the Chart Menu Annotate scrn22 Add comments in the Annotation Annotate field wares 71 Add time manually Eos EE 7 1 215702 vj 10 56 00 AM 25 Owell Ended 10 56 00 AM scrn23 A warning will appear on the display stating that once added the com ment cannot be deleted or changed Select The comment becomes part of the chart Review scrn24 OM 203 185 Page 43 Review Chart Save chart to floppy disk by select Ut ing File then select Save chart File Edi As scrn25 Select a path to Save Lave Enter File name to save as Review E E SF as the Instrument Job Batch Name for consistency Select Save Save w41 1307 2 5 Chart Group Files scrn26 scrn27 OM 203 185 Page 44 The file name becomes part of the chart T 11111111 1200000 scrn28 Review 1 234 WELDH5678 CGP Select File IE Edi Select Print to print entire profile on one page Print Ctri P scrn29 OM 203 185 Page 45 Select Batch Click in check box to select Print entire batch Print
34. adequate physical strength lift unit Move unit with hand cart or similar device e Forunits 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 FLYING METAL OR ADHESIVE 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 securely in place MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near induction heating operations OVERUSE can cause OVERHEATING e Allow cooling period Reduce output or reduce duty cycle before starting to heat again Follow rated duty cycle 1 4 California Proposition 65 Warnings 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 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 f
35. ained from http thermo electric direct com control interliant com Standard Quick Coupling Thermocouple Connectors7886 html 4 Calibration Labels Part No BLUE these can be obtained from http www q cees com itemdetail asp part 206 5 Alength of type K thermocouple wire connected between the type K mini connector and type K 2 pin connector Fluke 714 Thermocouple Calibrator Type K Mini Connector Type K 2 Pin Male Connector Calibration Labels Perform the procedure as follows 1 Press the down arrow on bottom left of digital recorder to display numeric page t Allow readings to stabilize before recording 2 Set Fluke 714 TC Calibrator to 382 0 degrees F a Move TC Calibrator from TC1 through TC6 in sequence recording each value read onto the Certificate of Calibration b Verify readings are within 3 degrees of TC Calibrator If readings are beyond the 3degrees F the instrument will need to be returned to Eurotherm for repair Phone 703 669 1316 E mail repairs eurotherm com web page www eurotherm3 com repairs htm c Repeat at 882 0 degrees and at 1382 0 degrees F 3 Save a copy of the Certificate using the IH TS serial no and date as the file name 1 056241 062501 for June 25 2001 Print a copy of the certificate to send with the IH TS 5 Complete calibration sticker and apply to IH TS front panel below recorder I D No IH TS serial no By your i
36. ange values Figure 6 4 Profile Set Up Worksheet OM 203 185 Page 25 6 3 3 Batch Recording Using 5100 Digital Recorder The batch file generated by the recorder will consist of GroupDescriptor BatchName TimeDateStamp uhh The default Group Descriptor is set to Group This setting may be changed to something that relates to the application i e Company Contract or Project name To change the Group Descriptor proceed as follows 1 59 epo lib 169 10 Log in as an Engineer see Section 6 2 2 2 Touch Menu bottom right Touch Operator Touch Config Touch Groups Touch the field next to Descriptor a keypad will appear on the display Enter the desired name and touch Ok Touch Apply Touch Menu bottom right Touch Home The Batch Name is entered by the operator This should be a unique name that identifies the part being heated Since the same part may have Pre heat P Bakeout B and Stress S procedures done to it the batch name should in clude an indicator as to which process was done i e W41 1307 2 S where the S indicates a stress procedure The Time Date Stamp and uhh file extension are both generated automatically by the recorder Begin Batch recording 6 3 3 1 Login As User 1 2 3 Touch top left corner Touch pull down next to User Touch User from pull down list 6 3 3 2 Start Recording 1 4 Il O 12 13 14
37. any open network applications Double click Local Area Connection desktop shortcut Click on Properties Scroll down to Internet Protocol TCP IP Click on Internet Protocol TCP IP to highlight it Click on Properties Click on Use the following IP address In the IP address field type 192 168 111 221 Click on Click on OK to add the subnet mask The Subnet mask field should display 255 255 255 0 Click on Click on Click on Close to close the Local Area Connection window For Windows 95 98 Close any open applications Windows will restart to apply settings Double click Network desktop shortcut Scroll down to Internet Protocol TCP IP Click on Internet Protocol TCP IP to highlight it Click on Properties Click on Specify an IP address In the IP address field type 192 168 111 221 Click on Click on Click on Yes to restart the computer and have changes take effect 6 3 3 5 4 Downloading Files From Recorder 1 2 Connect a crossover cable between the IH TS recorder and the PC a crossover cable is a special network cable with pins 2 and 3 reversed on one Start Review software see Section 6 3 7 OM 203 185 Page 28 7 Kt 3 Click on Instrument File Services 4 Click on Generic 5 Enter user name user leave password field
38. blank 6 Click on 7 Right click on desired files and transfer them following the procedures in Sections 6 3 6 and 6 3 7 6 3 3 5 5 Troubleshooting Connection Problems 1 Click on Start Programs Accessories Command Prompt 2 ping 192 168 111 222 Press Enter If the message Timed Out appears 4 times the recorder is not responding Check unit setup outlined previously and verify crossover cable is connected properly 6 3 3 5 6 Resetting IP Address Necessary To Connect User s PC To Company s Network For Windows 2000 Close any open network applications 2 Double click Local Area Connection desktop shortcut 3 Click on Properties 4 Scroll down to Internet Protocol TCP IP 5 Click on Internet Protocol TCP IP to highlight it 6 Click on Properties 7 Click on Obtain an IP address automatically 8 Click on 9 Click on 10 Click on Close to close the Local Area Connection window For Windows 95 98 1 Close any open applications Windows will restart to apply settings 2 Double click Network desktop shortcut Scroll down to Internet Protocol TCP IP 4 Click on Internet Protocol TCP IP to highlight it 5 Click on Properties 6 Click on Obtain an IP address automatically 7 Click on 8 Click on OM 203 185 Page 29 6 3 4 Running Progra
39. bove 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 1 05 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 otate 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 Heplacement Parts Training Schools Videos Books Technical Manuals Servicing Information 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 Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufactu
40. cally 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 Z49 1 listed in Safety Standards 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 properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conductor first double check connections safety ihom 5 05 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Frequently inspect input power cord for damage or bare wiring re place cord immediately if damaged bare wiring can kill T
41. cement 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 Effective January 1 2005 Equipment with a serial number preface of LF 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 instructions 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 date that the equipment was d
42. chperson 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 203 185 Page 1 FIRE EXPLOSION hazard e Do not overheat parts and adhesive e Watch for fire keep extinguisher 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 not operate unit in explosive atmosphere 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 e 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
43. eed to be deleted or a new database will need to be created Refer to the Review Manual for additional instructions When data is transferred to the review erv database the original uhh data file is simultaneously copied to the Master Archive Folder To change the location of the Master Archive Folder proceed as follows In Review software click Options Click Master Archive Folder Change the Master Archive Folder location as desired If a network drive is available multiple users can use the same database Refer to the Review Manual for further instructions Screens for changing the Master Fie view Instrument Options Help Archive Folder location Dark sles amp Fonts Master Archive Folder Enable Review Full demo Master Archive Folder setup Durning archive transfer operations all tiles will be backed up ta sub folders corresponding to instrument names within the folder specified below Masher Archive Folder C Program Files E urotherm H Browse Default ok Cancel scrn36 scm37 OM 203 185 Page 32 There three files used to produce a chart in Review software as follows 1 The uhh file contains the actual temperature data downloaded from the recorder 2 The c Program Files Eurotherm Review Review erv file contains a copy of the original data and any annotations added in the Review software The cgp file contains the chart graphical properties setup T
44. el Cycling 1 Press the Option key to open options menu 2 Press channel cycling On to activate cycling or press channel cycling Off to deactivate cycling E 4 3 To manually change which TC is Ho Bat 201525 displayed press the TC field to advance to the next reading 1 i Notes can be added to a chart on the recorder while viewing a trend Screen Press the Option Menu button Press Note Press the field next to User Note and enter notes using keypad Press OK Press OK The note is added to the chart The note can be viewed on the bottom of the screen or in the history screen Press the Option key press Enter History To exit press the Option key then press Exit History scrn34 OM 203 185 Page 18 6 3 Operation 1 Energize IH TS and power source A coolant flow error should appear on the IH TS display Energize the cooler and the error will clear from the display 2 Setup Temperature Profile per code requirements see Section 6 3 2 Programming The 2408 Controller 3 Setup and start Digital Recorder Digital Recorder see Section 6 3 3 Batch Recording On The 5100 Digital Recorder 4 Run the heat process see Section 6 3 4 Running A Heat Treat and the following tables 5 from an interruption if applicable see Section 6 3 5 Recovering From An Inter
45. elivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field 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 grea
46. ent consult power source Owner s Manual for troubleshooting Connect 14 pin control cable to power source Check for 24 volts dc between pins A and D at IH TS end of cable If 24 volts dc is not present replace 14 pin control cable Connect 14 pin control cable to IH TS Unplug IH TS 115 volts ac power cord Remove IH TS wrapper Check that plug PLG3 is fully inserted into receptacle RC3 on circuit board PC1 Check for loose wires in 14 pin receptacle and plug PLG3 Check for 24 volts dc between pins 7 and 15 at plug and receptacle RC3 If 24 volts dc is not present check wiring from plug PLG3 to receptacle RC10 Check that display ribbon cable is fully connected to receptacle RC1 on circuit board PC1 grey foil on pin 1 Check solder joints of ribbon cable to display Disconnect ribbon cable from display at receptacle RC1 Check for 5 volts dc between pins 1 and 2 at receptacle RC1 and proceed as follows If 5 volts dc is present replace the display if 5 volts dc is not present replace circuit board PC1 Reconnect IH TS 115 volts ac power cord B 2408 Temperature Controller Display Does Not Operate But 5100V Recorder Display Does Operate Remove and reseat 2408 controller module make sure that locking tabs are in place Remove IH TS wrapper Check for 115 volts ac between L and N at terminal strip on rear of controller module If 115 volts ac is present replace 2408 Temperature Controller if 1
47. er des travaux d entretien sur l appareil selon le manuel Porter un harnais de s curit pour effectuer des travaux au dessus du sol Maintenir solidement en place tous les panneaux et couvercles Ne pas toucher ou manipuler la t te l enroulement induction pendantle fonctionnement Tenir les bijoux et autres objets personnels en m tal loign s de la t te de l enroulement pendant le fonctionnement Laisser refroidir les composants ou quipements avant de les manipuler La mise en place de l appareil sur au dessus ou proximit de surfaces inflammables peut tre source d INCENDIES OU d EXPLOSION 1 Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables 2 Nepasinstaller l appareil proximit de produits inflammables 3 Ne pas faire fonctionner l appareil en atmosph re explosive DES FUMEES ET DES GAZ peuvent tre dangereux pour votre sant Le chauffage induction g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour votre sant Eloigner la t te des fum es Ne pas respirer les fum es A l interieur ventiler la zone et ou utiliser un extracteur pour l vacuation des fum es et des gaz Si la ventilation est insuffisante utiliser un respirateur alimentation d air homologu Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les adh sifs les m taux les consommables les rev tements
48. erator Screen 1 Touch the Menu key in bottom right corner to open Root Menu 2 Touch Operator 6 2 2 4 Locale Setup 1 Touch System Touch Locale Touch pull down next to Country Touch appropriate country Touch pull down next to Time Zone Touch appropriate time zone i e CST Central See http www timeanddate com for additional information od Set DST Daylight Savings Time if applicable Place an X the box next to Use Summertime DST to enable this option OM 203 185 Page 17 In general for those locations that observe DST DST begins at 2 00 am on the first Sunday in April DST ends at 2 00 am on the last Sunday in October See http deil lang uiuc edu web pages holidays DS T html for exceptions 8 Touch Apply 6 2 2 5 Time And Date Setup 1 Touch System 2 Touch Clock 3 Adjust time and date if necessary 4 Touch Apply 6 2 2 6 Login As User 1 Touch top left corner Engineer 2 Touch pull down next to User 3 Touch User from pull down list 6 2 2 7 Go To Home Screen 1 Touch the Menu key in bottom right corner to open Root Menu 2 Touch Home 6 2 2 8 Channel Cycling On Off And Notes When Trend graphs are displayed the operator has the option to sequentially display the TC readings for each channel by activating the Channel Cycling On option When channel cycling is off recorder displays only the selected TC value To activate deactivate Chann
49. eur cardiaque Consulter votre m decin pour un compl ment d information 2 3 PRINCIPALES NORMES DE S CURIT Normes de s curit et de sant OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Code lectrique national NFPA Standard 70 from National Fire Code lectrique du Canada partie 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 183 Safe Practices For Occupation And Educational Eye And Face Protection Association Batterymarch Park Quincy MA 02269 OM 203 185 Page 6 Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 SECTION 3 INTRODUCTION The Induction Heating Temperature Station IH TS is designed to be used with Induction Heating Systems for pre heat and post heat stress relieving applications The station is built in two different configurations as a controller only or as a controller with a digital recorder The controller in the IH TS comes pre programmed from the factory with a typical stress relieving temperature profile that can be easily changed to match specific customer stress relief requirements Also the controller can be programmed to operate in a pre heat mode These instructions will guide the operator in the proper use of the station which includes programming and setting up the controller
50. ington 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 systemes 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 scientifique courante ne nous permet pas encore d interpr terla preuve fournie dans un seul ouvrage coh rent Il est encore plus frustrant de ne pas pouvoir tirer des conclusions d finitives en ce qui concerne les probl mes de risque possible ou de Informations concernant les champs lectro magn tiques Information EMF proposer des recommandations scientifiques claires pour des strat gies suivre en vue de minimiser ou de pr venir des risques 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 stimulateurs cardiaques Les proc dures ci dessus concernent galement les porteurs de stimulat
51. l File name Multiple Files With No Batch Names Select archive data to transfer to database Look in 24 history 009842000000 4 uhh Miller wat 1307 4 STE amp 1 13021 5780 8009845 20000001 52 uhh 1 1307 2 5 800984 20000001 uhh Miller 41 130 2 5800964 20000007 54 uhh I Hiller 80098420000001 uhh Miller 8009 Files of type Packed Archive Files Cancel File name Data is continuously stored in the recorder The file name consists of Group Descriptor Batch Date stamp uhh Select the desired files Select Open If a batch was not started the temperature data is still recorded The Job Batch Name User Comments and Recorder ID are not recorded The file name would consist of Group Descriptor Time Date stamp uhh no Batch Name The file creation time can be found using the Detail Button Select the desired files Select Open 2 0 ment automatic batch names Cancel Prompt for Instrument tag and Batch name for each Allfiles from one instrument automatic batch names vat 1307 2 5 Select or Enter Instrument tag Enter the Job Batch Name in the field next to Select or Enter In strument tag This is the File name the informa tion will be stored in Select OK Proceed to New Instrument pop up window top of page 37 scrn10 OM 203 185 Page 37 Chart
52. leads for continuity when switch is activated Check switch leads for open circuit when switch is deactivated If continuity is always present at switch leads replace flow switch E Heat On Light Does Not Display When Power Source Is Supplying Output Remove IH TS wrapper Check for 24 volts dc at LED this LED is polarity sensitive red mark on plastic lense is side If 24 volts dc is present replace LED If 24 volts dc is not present another source rather than the IH TS is energizing the power source Check for a short circuit between pins A and B in the 14 pin control cable F Output Does Not Start When Run Button Is Pressed Check for 5 br on 2408 Temperature Controller display Fully press and release Stop and Hold buttons then try pressing the Run button If actual temperature is higher than target temperature see recovery procedure in Section 6 3 5 Remove 14 pin control cable from IH TS Jumper pins A and B in plug on 14 pin cable If no output is present proceed as follows Remove 14 pin control cable from power source Jumper pins at power source receptacle If no output is present consult power source Owner s Manual for troubleshooting If output is present replace 14 pin control cable If output is present proceed as follows Unplug IH TS 115 volts ac power cord Check Run Hold and Stop switches for operation G Pressing Power Source Select Button On Rear Of IH TS Does Not Change Selection Remove IH TS w
53. m Preheat Or Stress Relief To start the Heat Treat operation proceed as follows Press the RUN button The blue Heat On light turns on and the power source energizes The power source parameters are displayed on the Parameter Display The controller flashes Hold until the measured temperature climbs to within the Hold Back window 109 of the target temperature To adjust profile during the Heat Treat operation proceed as follows Press the HOLD button The controller displays HOLD but the heat is maintained at the present target temperature Press Page button until Prob Li appears on the display Press Scroll button to select the desired parameter for changing Use A Or or Down button to change value Press B Page button until parameter screen appears on the display Press RUN button to resume program When cycle completes or to abort the process fully press the STOP button controller resets to segment 1 and power source contactor relays open 203 185 Page 30 6 3 5 Recovering From An Interruption Press the RUN button to start profile There are two conditions the controller looks at to determine 1 If it should supply output power and 2 If the power source contactor should be on 1 If the current temperature is more than 10 F above the target temperature in segment 1 the IH TS will not require output from the power source The blue
54. me Setup Touch System Touch Clock Adjust time if necessary Touch Apply 7 3 4 Login As User 1 Touch top left corner Engineer 2 Touch pull down next to User 3 Touch User from pull down list 7 3 5 To Home Screen 1 Touch key in bottom right corner to open Root Menu 2 Touch Home OM 203 185 Page 51 SECTION 8 MAINTENANCE amp TROUBLESHOOTING 8 1 Routine Maintenance Heplace Cracked Parts Unreadable Labels 8 2 Troubleshooting Trouble Remedy IH TS does not power up Be sure that power switch on rear of IH TS is in the On position Check 115 volts ac at receptacle where IH TS is plugged in Be sure that IH TS is not plugged into a switched receptacle Check power source primary power for 3 phase 400 or 460 volts ac depending on model Replace building line fuse or reset circuit breaker For 5 kW PWHT cart remove transformer cover on back of running gear and check terminal strip jumpers to verify they are set in the correct position For 25 kW PWHT system cart remove transformer cover on back of running gear and check for loose lead connections Display flashes Gbr Thermocouple open connect thermocouple Two pin thermocouple plugged into ground copper pin reconnect to the two silver pins Display flashes Workpiece actual temperature is more than 25 degrees over the target temperature Wait f
55. me reason 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 252 exact part you may need to fix 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 Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 151 NY SAS PP PEPPER P 1 1 2 Induction Heating Hazards RE P Re ERR CERE ER Ce Reb mc RR a da 1 1 3 Additional Symbols for Installation Operation and Maintenance 2 1 4 California Proposition 65 06 0 2 iPuncipal Satety Standards du rg done 2
56. mperature program that is entered in Prog List The configuration of the controller contains two important elements that dictate how the controller switches between segments and how it protects against over temperature conditions One element is called Holdback This is a temperature window that the controller uses to determine the point at which it switches from segment to segment The window is set to 10 When operating within a temperature pro file the controller will not advance to the next segment until the actual temperature comes within 10 of the target temperature The second element is an alarm This alarm value is set at 25 F When the actual temperature exceeds the target temperature by 25 F the controller shuts off the power source contactor to prevent overheating the part When the temperature falls 2 F below the alarm temperature the controller re energizes the power source output OM 203 185 Page 20 6 3 2 Programming The 2408 Controller Identify the code requirements for the heat treat For Preheat program refer to Figure 6 1 For Postweld stress relief program refer to Figure 6 2 For a complex stress relief program multiple temperature rise and cool rates refer to Figure 6 3 Use worksheet in Figure 6 4 to help prepare either a pre or post heat temperature profile Table 6 3 Program List Terms And Definitions BEL Segment number Segment Type Definitions otep The setp
57. n of data transfer 8 Touch key in bottom right corner to open Root Menu 9 Touch Home 10 Remove floppy disk 11 To view data go to Section 6 3 6 6 3 3 5 Saving Data To A PC Alternative To Floppy Disk 6 3 3 5 1 Review Software First Time Setup 1 Start Review software see Section 6 3 7 Click on Instrument Setup TCP IP Click on Add Instrument In the TCP IP Address or Host field type 192 168 111 222 2 4 5 Identifier field type Generic 6 Click on 6 3 3 5 2 Creating A Shortcut First Time Setup Local Area Network Connection Windows 2000 1 Click on Start Settings Control Panel Open Network and Dial up Connections Right click on Local Area Connection Select Create Shortcut 919 Click on Yes to create shortcut on the desktop OM 203 185 Page 27 1 p 3 4 5 6 uem OX iem opos N gt gt O oP 4 10 Close the Network and Dial up Connection window Close the Control Panel Network Connection Windows 95 98 ME Click on Start Settings Control Panel Right click on Network Select Create Shortcut Click on Yes to create a shortcut on the desktop Close the Control Panel 3 3 5 3 Changing IP Address To Connect The IH TS For Windows 2000 Close
58. nes Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and oth er reproductive harm Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rex dale Ontario Canada M9W 1R3 Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi 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 u
59. nitials Date today s date Due date 1 year from today OM 203 185 Page 65 SECTION 9 ELECTRICAL DIAGRAMS ho E o 2 i J o pd p o c o e WARNING Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install ELECTRIC SHOCK HAZARD use or service this unit MWM 005 tl Hl Me o ARA AY g 0128 lt 3EMAO2 31242 LE dc bis dac sh 442 ANAL H3AO 88 88 55 88 88 55 L rr rr rr rr rr rr gl 20A 01 0 lt 27 iind ue 4l gg LALA gt QNS v i Mh e Woo SPL E ON Soe 98 N OLOU 27 sw lt lt 6 W 0LO3 lt 8 9y 21 1 010 2 3v lt lt 9 9u LT 25775 pne 1 019 77 502 698 z sa 8 299 14 0194 2 lt lt 41 v z gt gt gt Nonno lt lt 77 pee lt lt 5 172087077 01i RERUM a e e 1 6 8 6 1 1 to c c nnn tert mnm ANA O00 FFF FFF FFE EEF eS TC1 TC1 GND NOIL23NNO2D XBH
60. o prevent loss of data due to software or hardware failure all three file types should be backed up on a regular basis 6 3 7 Running Review Software T Accessories Start Review software Adobe Acrobat 4 0 mn Startup Command Prompt Windows NT Explorer Intemet Explorer ay Windows Explorer AJ windows MT Explorer Programs zi Documents uel Administrative Tools Common Eurotherm i i Explore D ocumentaion Settings Lol Startup Find Seres 6000 Configuration Editor Help Run Shut Down A ET Insert floppy disk with desired file View Instrument Options Help into floppy drive on pc chart Ctrl M Select File Open chart Select Transfer Files Transfer Files Maintain Database Page Setup 1 C TEMP Bermal Chart 1 CGF 2 CXTEMP Bermal Chart 2 CGP Exil OM 203 185 Page 33 J Select Files m Review File View Instrument Options Help chart Open chart Transfer Files Automatic Print From Folders Maintain Database From Removable Media scrn38 Select archive data file to transfer to database 5 Select the history folder on the floppy drive or browse to the folder Look in 25 Floppy amp l Eg on the PC that contains the uhh files History Files of type Packed Archive Files Cancel OM 203 185 Page 34 Single File With Batch Name L
61. oint steps instantaneously from its current value to a new value SLEEP Dwell The setpoint remains constant for a specified period a Dwell units are in hours Ramp Time The setpoint ramps linearly from its current value to a new value either at a set rate called ramp rate programming or in a time called time to target Ramp Rate programming You must specify the ramp rate or the ramp time and the target mPr setpoint when creating or modifying a program Ramp units rmP Ll are in hours End A program either ends in this segment or repeats You specify which is the case E n d when you create or modify a program see the final topic in this chapter When a program ends the programmer is put into either a continuous Dwell state with all outputs staying unchanged or the Reset state The following parameters are available depending on the ETF selected ENT AR RE ee Ramp rate for a r m pgs segment Dwell time for a we segment __ S o Ent prog H 5 UP OM 203 185 Page 21 Step to 300 F as fast as possible OM 203 185 Page 22 Free fall to Dwell 300 for 8 hours ambient O1 eo Degrees F N N O O O O O O Oo Example Pre heat Profile 30 40 Time minutes Figure 6 1 Setting Pre heat Profile Using Example Parameters Step to 600 F Ramp to 1350 Dwell
62. ook in 4 history amp Miller 800984200000014 uhh Milerw41 130 2 578 amp Hiller 200988 20000007 60 uhh iler amp Miller 80098420000001 52 uhh amp Miller gissa 2000000157 uhh Miller w41 1307 2 5 8003852000000153 uhh amp 41 1307 2 S 780038552000000154 uhh Filename Miller w41 1321 1 5780038820000001 4B uhh Files of type Packed Archive Files Cancel Select the desired file highlight file name The file name consists of Group Descriptor Batch Name Time Date stamp uhh For example Miller W41 1321 1 S 80098A200000014B uhh Select Open Transfer File name A histon Mille 8420000007 46 uhh Lag group Lab Log start time O21 5 02 07 04 10 125 Enter the Job Batch Name in the field next to Select or Enter w41 1307 1 5 Instrument tag Select or Enter Instrument tag This is the File name the Enter Batch Name if required w41 1307 1 5 stored Proceed to New Instrument op up window top of page 37 Start Transfer Cancel pop up top of pag E OM 203 185 Page 35 Single File With No Batch Name Data is continuously stored in the recorder Select archive data to transfer to database y If a batch was not started the temperature pum data is still recorded Job Batch Look in history Name User Comments and Recorder ID Miller HMiler 41 130 2 50
63. or workpiece temperatureto drop or follow the recovery procedure in Section 6 3 5 Power source contactor turns On Change Panel Remote switch on power source to Remote position and Off at 25 over target temperature LanF appears on the display Press the ut arrow to change the U toc Press scroll to enter the menu Press page to E change itto Er YES and the controller will reset automatically If display flashes na a Remove 2408 control from its housing by pressing locking tabs outward slightly on sides of control and pulling control forward Look for add on PC card in back of controller and check that white connector is fully inserted into 2408 control Reinstall 2408 control into housing being careful not to damage locking tabs on housing OM 203 185 Page 52 Trouble Remedy If display flashes na again or if 0 10 V output card fails Remove 2408 control from its housing by pressing locking tabs outward slightly on sides of control and pulling control forward Look for add on PC card in back of controller and remove PC card Reinstall 2408 control into housing being careful not to damage locking tabs on housing Disable output card function as follows Loko Lonf i H LanF Module 1 Config See Section 8 5 4 Change d dc DF toi d Scrollto Er no and change it to E YES and the controller will reset automatically Set power source panel remote switch to
64. order 8 4 Resetting All RAM Variables In The Event Of Display Errors This procedure will reset all Helease Button stored variables in memory including scaling programs counters and security code Before turning on power at the power source press and hold Power Source Select button Turn on power at power source Press 1 Release Button Display When Release Button appears on the display release the button To Reset 2 Press Power Source Select To Reset Display Power Source Select After the display changes to Press Power Source Select To Reset press Power Source Select button to reset all stored variables in RAM 3 RESETTING MEMORY Display RESETTING MEMORY will appear on the display automatically during the RAM memory reset operation 4 MEMORY RESET Display MEMORY RESET will appear on MEMORY RESET the display after completion of RAM memory reset The IH TS will restart with factory set default parameters in RAM memory RESETTING MEMORY i OM 203 185 Page 58 8 5 Factory Set Parameters If it becomes necessary to return to factory settings the following sections list factory settings for the 2408 controller All settings can be accessed through the Goto screen To access the Goto screen proceed as follows Press Page B to Press Scroll 0 codE wait 2 sec After selecting the desired Goto screen press the scroll button to display
65. p ramp rate ramp rate soak ramp rate ramp rate end ELE ELE ELE dur ELE ELE End E UL 12050 5 0 deg deg deg in hrs deg deg sets output to O C3 deg hr deg hr deg hr deg hr Example Multi Step Stress Relief Profile Degrees F eo O 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 Time hours small diameter pipe it may be necessary to reduce the output of the power source to achieve a reasonable rate in Segment 1 thereafter the program controls the rate of temperature rise and the output power may be increased to full if desired To reduce output power turn power source output knob to desired setting Figure 6 3 Setting A Complex Stress Relief Profile With Multiple Temperature Rise Cool Rates Using Example Parameters OM 203 185 Page 24 SEL SEL SEU SEL 3 5 EVPE EVPE EVPE EVPE EYPE DEEP rmP r End step ramp rate soak ramp rate end A B D E ELE ELE dur ELE End E E Ll 5 target target duration target sets output to 0 deg deg in hrs deg C F deg hr deg hr Identify Target 3 Program controller with Press Scroll button to advance temperatures Ramp Profile using Navigating to each screen Rates and Dwell Time buttons Press Page button until Prob Press Up or Down button to Insert Values into profile Li 5E appears on the display ch
66. panel position and set desired maximum output The control will operate in an on off mode at target temp over temp alarm value The over temp alarm value is set Loko Full AL Li 5b dH Obtain a replacement 0 10 V isolated card Output stops when green Run button is released Replace Hold button Temperature readings go down instead of up Check for reversed red and yellow leads in 2 pin thermocouple and correct if necessary Temperature readings do not rise Check for a short between thermocouple wires Temperatue does not change in ramp segment Change the ramp rate for that segment in the Program List Fault Limit light is on Parameter Display will indicate either Coolant Flow Error or PS Limit Coolant Flow Error ensure that cooler is plugged and turned on For 25 kW system ensure receptacle switch is on Check coolant level in reservoir and add coolant if necessary Check filter on cooler and replace if necessary Verify that coolant and OUT hoses are connected to the correct fittings Check alignment of center pins in plastic quick disconnect fittings Be sure that coolant jumpers are connected properly PS Limit indicates the power source will run at less than full output Verify panel remote switch on power source is in Remote position Turn down dial on front panel of power source until light goes out or To obtain full out
67. ppears on parameter display proceed as follows Remove Fault Limit amber lense and bulb Check for 115 volts ac at light socket If 115 volts ac is present replace Fault Limit bulb If 115 volts ac is not present proceed as follows Remove IH TS wrapper Check for 115 volts ac between pin 13 at receptacle RC3 and neutral switch 51 1 lead 2 If 115 volts ac is present check wiring for Fault Limit light PL 2 If 115 volts ac is not present check for 115 volts ac between pin 14 at receptacle RC3 and neutral switch 51 1 lead 2 If 115 volts ac is present replace circuit board PC1 If 115 volts ac is not present check wiring from pin 14 at receptacle RC3 If no error message appears on the parameter display proceed as follows Unplug IH TS 115 volts ac power cord Remove IH TS wrapper Check for an open circuit at RC3 between pins 17 and 18 If circuit is open replace circuit board PC1 If circuit is not open consult power source Owner s Manual for troubleshooting Reconnect IH TS 115 volts ac power cord If light illuminates disconnect Coolant In red fitting from IH TS opray silicone lubricant into fitting Insert a long narrow screwdriver into fitting and actuate flow switch plunger several times Remove IH TS wrapper Disconnect flow switch leads OM 203 185 Page 56 Check Flow Limit light for illumination If light does not illuminate replace circuit board PC1 If light does illuminate proceed as follows Check switch
68. put adjust the coil to get more coupling into the part Check set up parameters If Volts setting is greater than 650 add a turn to the heating coil Current Source fault Remove a turn from the heating coil Power Volts equals Real Current Real Current must be kept under 60 A 2408 Controller displays dwell Check that Hold Back setting is in Band display will read Hb bHnd see Section 8 5 3 Loto Full Prob before 10 degree window is Li GE reached che that Hold Back Units equals 10 F display will read see Section 8 5 3 baba Full Prob Parameter display does not See Section 8 3A operate but 2408 Temperature Controller and 5100V Recorder displays do operate 2408 Temperature Controller display does not operate but 5100V Recorder display does operate See Section 8 3B 5100V Recorder does not turn on but 2408 Temperature Controller does turn on See Section 8 3C Flow Limit light does not illuminate when cooler is turned off See Section 8 3D Heat On light does not display when power source is supplying output See Section 8 3E Output does not start when Run button is pressed See Section 8 3F Pressing Power Source Select button on rear of IH TS does not change selection See Section 8 3G 5100V Recorder displays Channel Error See Section 8 3H OM 203 185 Page 53 Trouble Remedy 2408 Tempera
69. r d placer ou exp dier des cartes PC Il subsiste DU COURANT CONTINU IMPOR TANT apr s la mise hors tension de l alimen tation lectrique 1 Avant de toucher des organes internes arr ter la source lectrique d brancher l alimentation et d charger les condensateurs d alimentation conform ment aux instructions indiqu es dans la partie main tenance LE RAYONNEMENT HAUTE FREQUENCE peut provoquer des interf rences avec les quipements de radio navigation et de com munication les services de s curit et les or dinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation L utilisateur 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 r gulierement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence OM 203 185 Page 5 2 2 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 Congr s U S Office of Technology Assessment Effets biologiques des champs magn tiques et lectriques basse fr quence Background Paper OTA BP E 53 Wash
70. rapper Jumper across leads at Power Source Select button dry circuit If selection changes replace switch If selection does not change proceed as follows Jumper between pins 1 and 2 at RC2 on circuit board PC1 If selection changes replace wiring to the switch If selection does not change replace circuit board PC1 H 5100V Recorder Displays Channel Error will not operate below 32 allow 15 30 minutes for warm up or move recorder to a warmer location Remove IH TS wrapper Remove red cover on rear of recorder Check that terminal strip is secure on rear of recorder OM 203 185 Page 57 Ribbon cable may be disconnected inside of recorder after prior maintenance reconnect ribbon cable If above procedures do not clear the error message replace recorder l 2408 Temperature Controller Reads Greater Than 5 Different Than Channel 1 On 5100V Recorder Remove IH TS wrapper Check that red and yellow leads are secure between clamp and copper pad on rear of temperature controller Connect a thermocouple to TC1 input If temperature controller drifts while power source is off replace temperature controller If recorder readings drift while power source is off replace recorder If power source output varies audible frequency change while attempting to maintain temperature replace temperature controller If recorder readings drift while temperature controller is maintaining temperature replace rec
71. rer s Transportation Department PRINTED IN USA 2005 Miller Electric Mfg Co 1 05 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 Miller
72. riate 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 IMPLIED 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 a
73. rocedure The possible hazards are shown in the adjoining symbols Means Note not safety related 1 2 Induction Heating Hazards 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 Safe ty Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill JN Touching live electrical parts can cause fatal shocks or severe burns The power circuit and output bus bars or connections are electrically live whenever the output is on The input power circuit and machine 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 Additional safety precautions are required when any of the follow ing electri
74. rom Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safety and Health Standards 5 29 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 203 185 Page 2 STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 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 person familiar with electronic equipment 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 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 Miller Hobart replacement parts For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engi
75. ruption 6 Retrieve data Digital Recorder see Section 6 3 3 4 Batch Recording On The 5100 Digital Recorder View and print data see Section 6 3 6 Review Software Table 6 1 Controller Display Definitions Description Home List extra parameters may be present Measured value and Setpoint Output level PSP pre Program time remaining in hours Flash active segment type in the lower readout of the home display no YES Runs through program 10 times faster than normal This parameter can only be changed when the program is in reset OM 203 185 Page 19 6 3 1 2408 Controller The 2408 controller the IH TS provides means of establishing a heat profile for heating or stress relieving as dictated by code requirements and controls the power source to meet the programmed profile The 2408 controller has several screens main and sub menu that are used to monitor status and program the control The main screens are as follows Home Screen Run List Program List Access List This screen is displayed after first turning on the unit It has the actual temperature at the top of the display and program temperature at the bottom of the display Home Screen sub menu and definitions are shown in Table 6 1 Pressing the Scroll button will step through the sub menus This screen is accessed by pushing the Page B key twice Run List allows the operator to check the status of a program while the system i
76. s 0 Colour IB Alarm Number 1 Enable Off Y Job Number 1 Category No Action Y Log out 5 33 203 185 49 7 3 Restoring Recorder Configuration From A Floppy Disk For 5100 Digital Recorder Login as Engineer Touch top left corner Logged Out or User Touch Blue text pull down menu next to User Touch Engineer Touch Password field Touch Numeric Touch 1 then 0 then Ok 7 3 1 Load File Insert digital recorder configuration disk into recorder Touch key in bottom right corner to open Root Menu Touch Operator Touch Save R Touch Restore Touch field next to File Name Touch up folder Touch Floppy Highlights yellow Touch down folder Touch the desired 5100 Config file uhz Touch Open 7 3 2 Date Setup Touch System Touch Locale Touch pull down next to Country Touch appropriate country Touch pull down next to Time Zone Touch appropriate time zone i e CST Central See http www timeanddate com for additional information A Ok OL sb oS Set DST Daylight Savings Time if applicable Place an X in the box next to Use Summertime DST to enable this option In general for those locations that observe DST DST begins at 2 00 am on the first Sunday in April DST ends at 2 00 am on the last Sunday in October See http deil lang uiuc edu web pages holidays DST html for exceptions 8 Touch Apply OM 203 185 Page 50 7 3 3 Ti
77. s running It also allows making changes to a program by pressing the Hold button on the front of the IH TS Run List sub menu screens and their definitions are shown in Table 6 2 This screen is accessed by pushing the Page B key three times Program List is used to program the controller for a pre heat or stress relieving temperature profile Definitions of the various terms found in the sub menu screens are shown in Table 6 3 Typical programming examples are shown in Figure 6 1 Figure 6 2 and Figure 6 3 This screen is used to access the configuration and set up sub screens within the controller This area is password protected and should only be used by an experienced operator Making changes in the Access List screens may cause the system to operate incorrectly A series of keys at the bottom of the 2408 controller are used to navigate between and change values in the various screens on the controller display Definition of the keys are as follows The Page B key advances the controller display between main screens Run List Prog List and Accs List The Scroll key advances between various sub menu screens in the main menus The Up A and Down keys are used to change values the sub menu screens t The two small round buttons on the front of the controller are disabled and nonfunctional 6 3 1 1 2408 Controller Operation The 2408 controller is configured to control the power source to achieve the te
78. s to draw definite conclusions about questions of possible risk or to of 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 or drape output cable around the body 3 Keep power source and cable as far away from the operator as practical About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding or induction heating operations If cleared by your doctor then following the above procedures is recommended OM 203 185 Page 3 SECTION 2 MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION ihom fre 8 03 AVERTISSEMENT PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES VOIRE MORTELLES TENIR LES ENFANTS A DISTANCE LES PORTEURS D UN STIMULATEUR CARDIAQUE DOIVENT PREALABLEMENT CONSULTER LEUR MEDECIN Pendant les op rations de chauffage comme dans la plupart des activit s l op rateur s expose certains dangers Le chauffage n est pas dangereux condition de prendre certaines mesures Les consignes de s curit indiqu es ci apr s ne sont qu un r sum des informations plus d taill es se trouvant dans les normes de s curit num r es la page suivante Lire et respecter toutes les normes de s curit LES OPERATIONS D INSTALLATION DE FONCTIONNEMENT DE MAINTENA
79. ter m Miller 4 6 Months Batteries 5 90 Days Parts Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers 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 Equipmentthat 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 INTENDED 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 approp
80. the menu Press the page button to move from left to right through the columns press the scroll button to move down the column press the up or down arrow to change parameter settings if necessary 8 5 1 Controller Version Number When the controller is first turned on the version number will display breifly and appear as shown Controller configuration parameters vary based upon version number See appropriate Section for the corresponding version number Version Number V4 09 Effective w Serial No LC089021 OM 203 185 Page 59 2408 Controller Edit Parameters 8 5 2 suomgonujsui 20 6 9 0 J89JeH L JP n JP 48751 JP JP JP JP PHJ do d5 un H je 1511 1511 1511 1511 1511 1511 1511 1511 1611 1 5 aid eunjoiny C 049 L3 LI LU Un CE 277 Un Cc LL L H L3 u L a LL aU u c CC aU LU LI u CC L H Lu wn ch n un Co Lo gt Lj u Un LL PHJ L u 2 Lt wn Co 1811 ung gt LLI Lt LL c n L n a Cc Lu 1811 1019S
81. ture Controller reads See Section 8 3l greater than 5 different than Channel 1 on 5100V Recorder 2408 Temperature Controller Check and secure connections to the workpiece readings fluctuate rather than remain stable 5100V Recorder screen blinks Screen calibration needs adjusting Turn off IHTS power switch Turn on IHTS power switch while touching when touched but does not screen and continue to touch screen about 45 seconds until configuration display appears on the screen advance to next screen Press Touch or wait a few minutes for the Touch Cal display to appear on the screen Use a pointed object be careful not to damage screen and touch each set of cross hairs to calibrate screen When calibration is complete turn IHTS power off and back on again 5100V Recorder does not recognize Floppy disks do not work well in ambient temperatures greater than 104 F 40 C floppy disk Clean floppy drive with a disk drive cleaner available from a local computer reseller OM 203 185 Page 54 8 3 Diagnostic Procedures For IH TS A Parameter Display Does Not Operate But 2408 Temperature Controller And 5100V Recorder Displays Do Operate Turn on power source Remove 14 pin control cable from power source and IH TS Check for bent pins in 14 pin control cable and on IH TS receptacle Check for 24 volts dc between pins and D at power source receptacle If 24 volts dc is not pres
82. upplied with ES internal coolant flow switch NX Coolant hoses must be connected 2 to the 5 for proper operation Connect coolant hoses supplied with post heat systems to coolant 3 fittings on unit as described in EE EE EEE Section 4 5 Tools Needed 11 16in Ref 803 003 OM 203 185 Page 12 SECTION 5 COMPONENTS AND CONTROLS 5 1 IH TS Front Panel Keep all panels doors and covers closed and secure during programming Temperature Controller Parameter Display Screen Heat On Pilot Light Fault Limit Light Run Button Hold Button Stop Button Recorder If Equipped Ref 803 004 OM 203 185 Page 13 5 2 5 Rear Panel OM 203 185 Page 14 Keep all panels doors and Cb c mm covers closed and secure during programming Thermocouple Connectors On Off Power Switch 115 VAC Power Cord 14 Pin Receptacle Coolant Flow Switch IN Fitting Coolant Flow Switch OUT Fitting Power Source Select Switch Network Connection Ref 803 004 A 5 3 Controller Keep all panels doors and covers closed and secure during programming Digital Display Page Forward Button Scroll Button Down Button Up Button Actual Temperature Setpoint Temperature Auto Man Button Disabled Run Hold Button Disabled V UMS sep Tace OM 203 185 Page 15 SECTION 6 SETUP AND OPERATION 6 1 Safety Equipment
83. urn 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 hazardous 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 e 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 wat
84. urs 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 oxyg ne et provoquer des l sions ou des accidents mortels S assurer que l air ambiant ne pr sente aucun danger Ne pas chauffer dans des endroits se trouvant proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur peut r agir en pr sence de vapeurs et former des gaz hautementtoxiques et irritants Ne pas chauffer des m taux munis d un rev tement tels que l acier galvanis plaqu au plomb ou au cadmium moins que le rev tement ne 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 chauff s Dangers suppl mentaires de mise en route de fonctionnement et d entretien UNE UTILISATION INTENSIVE peut provo quer un SURCHAUFFEMENT DU MATERIEL 1 Pr voir une p riode de refroidissement 2 R duire le courant de sortie ou le facteur de marche avant de recommencer le chauffage 3 Respecter le facteur de marche nominal L ELECTRICITE STATIQUE peut endomma ger les composants des tableaux lectri ques 1 Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces 2 Utiliser des pochettes et des boites antistatiques pour stocke
85. witch replacement for 203 135 including 1 VETTER 203 135 SWITCH pb mc SPST 1 115VAC green 1 REDE 210 369 BOOT switch pushbutton 1 292027 691 HOUSING x eur ro ih eit DE Dette a eratis KERN 027629 s 1BULB NCA 35 5 th eere td ad csi acd uds ch sd CER 176 246 LENS utr eh ee RE Oe 7 idR 42 2222 1970962 c WED DING ae re eme coin dd etta oo IEEE e dd 43 202200 TEMPERATURE CONTROLLER 1 ET a eN 192457 sr CORD DOWGET ren ae La E s bet e pae uos 71 When ordering a component originally displaying a precautionary label the label should also be ordered replacing a boot only onto an existing switch apply a silicone spray on both boot and switch to prevent moisture buildup inside boot and ease installation 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 203 185 Page 68 Notes Notes 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 repla

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