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Miller 907271, Owner'S Manual

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Miller 907271 Owner'S Manual Download Page 81

OM-222166 Page 75

Quantity

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-8. Left Windtunnel (Continued)

PLG16,

. . . . . . .

121,122

131054

Housing Rcpt+Skts, (Service Kit)

3

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG19,

. . . . . . .

120

115094

Housing Plug+Skts, (Service Kit)

2

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG15,

. . . . . . .

118

115093

Housing Plug+Skts, (Service Kit)

2

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG77,

. . . . . . .

119

115092

Housing Plug+Skts, (Service Kit)

2

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG17

115091

Housing Plug+Skts, (Service Kit)

1

. . . . . . . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18,

. . . . . . .

116

131056

Housing Rcpt+Skts, (Service Kit)

2

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13,

. . . . . . .

113

162382

Housing Plug+Skts, (Service Kit)

2

. . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14

130203

Housing Plug+Skts, (Service Kit)

1

. . . . . . . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

Summary of Contents for 907271

Page 1: ...rocesses Description Induction Heating Power Source Induction Heating OM 222166AH 2016 12 File Induction Heating Visit our website at www MillerWelds com CE And Non CE Models For Stock Nos 907271 907298 and 907432 ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ...ECTION 5 INSTALLATION 12 5 1 Selecting A Location 12 5 2 Dimensions And Weights 12 5 3 Electrical Service Guide 13 5 4 Connecting 3 Phase Input Power For 460 575 Volt Models 14 5 5 Connecting 3 Phase Input Power For 400 460 Volt IEC And CE Models 16 5 6 Coolant Jumper Connections 17 5 7 Power Source Output Connections 18 5 8 Remote 14 Receptacle RC14 Information and Connections 19 5 9 Remote 14 So...

Page 4: ...4 SECTION 8 MAINTENANCE 46 8 1 Routine Maintenance 46 8 2 Calibration Verification Equipment 47 8 3 Calibration Verification Procedure 47 8 3 1 Initial Set Up 47 8 3 2 TC Input Output Check 47 8 3 3 Finishing Procedure 48 SECTION 9 SAFETY PRECAUTIONS FOR SERVICING 51 9 1 Symbol Usage 51 9 2 Servicing Hazards 51 9 3 California Proposition 65 Warnings 52 SECTION 10 DIAGNOSTICS TROUBLESHOOTING 53 10 ...

Page 5: ...etic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources IEC 60974 10 2007 Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc...

Page 6: ......

Page 7: ...457 mm to provide isolation D Properly install ground and operate this equipment according to its Owner s Manual and national state and local codes D 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 D When making input connections at...

Page 8: ...tion Publication No 94 110 when manually lifting heavy parts or equipment FLYING METAL OR DIRT can injure eyes D Wear approved safety glasses with side shields or wear face shield MOVING PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance...

Page 9: ...A 02269 phone 1 800 344 3555 website www nfpa org and www sparky org CanadianElectrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standar...

Page 10: ...ce à souder ou le sol Dans ces conditions voir ANSI Z49 1 énuméré dans les nor mes de sécurité En outre ne pas travailler seul D Couper l alimentation d entrée avant d installer l appareil ou d effec tuer l entretien Verrouiller ou étiqueter la sortie d alimentation selon la norme OSHA 29 CFR 1910 147 se reporter aux Principales nor mes de sécurité D N utiliser que des tuyaux de refroidissement no...

Page 11: ...e indiqué dans le manuel d utilisateur D Tenir les bijoux et autres objets personnels en métal éloignés de la tête de l enroulement pendant le fonctionnement D Ne pas toucher aux pièces chaudes utiliser les outils recom mandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures 2 3 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenanc...

Page 12: ...e 800 463 6727 website www csagroup org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 webs...

Page 13: ...or parts Safe74 2012 07 Do not wear metal jewelry and other metal personal items such as rings and watches during operation Safe75 2012 07 Induction heating sparks can cause fire Do not overheat parts and adhesives Safe76 2012 07 Keep flammables away from heating operation Do not heat near flammables Safe77 2012 07 Heating sparks can cause fires Have a fire extinguisher nearby and have a watchpers...

Page 14: ...Waste Electrical and Electronic Equipment WEEE by disposing at a designated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 V A Consult rating label for input power requirements Safe34 2012 05 Become trained and read the instructions and labels before working on machine Safe35 2012 05 Disconnect input plug or power before wor...

Page 15: ...me symbols are found only on CE products A Amperage V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Protection Output Increase Line Connection I1 Primary Current I2 Rated Current U1 Primary Voltage U2 Load Voltage Read Instructions Three Phase Static Frequency Converter Transfo rmer Frequency Converter I1max Rated Maximum Supply Current P1max Maximum Power Consump...

Page 16: ...0 A 50 A 40 A 39 37 4 3 Environmental Specifications A IP Rating IP Rating IP23C This equipment is designed for outdoor use It may be stored but is not intended to be used for welding heating outside during precipitation unless sheltered Ref IP23 2014 06 B Information On Electromagnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical p...

Page 17: ...nt temperature above 14 F 10 C 20 4 25 13 Store dry Store dry Store dry 30 22 35 31 40 40 277088 A Not Recommended With Qualifications ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇNormal Operation With Coolant NOTICE The Miller ProHeat 35 Rolling Inductor is rated for operation between 14 F and 140 F 10 C to 60 C For operation at 40 F to 14 F 40 C to 10 C take the following precautions to prevent equipment ...

Page 18: ... forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input power supply 5 1 Selecting A Location 3 18 in 460 mm 18 in 460 mm OR 1 2 Movement Location And Airflow loc_large 2015 04 Do not move or operate unit where it could tip 803992 B 18 in 460 mm 18 in 460 mm 5 2 Dimensions And Weights 803 992 B B C A Dimensions A 27 5 in 699 mm B 21 75 in 553 mm C 36 75 in 933 m...

Page 19: ...t Breaker Rating In Amperes 1 Circuit Breaker 1 Time Delay Fuses 2 70 61 45 Normal Operating Fuses3 80 70 60 Min Input Conductor Size In AWG 4 6 8 8 Max Recommended Input Conductor Length In Feet Meters 254 77 214 65 334 102 Min Grounding Conductor Size In AWG 4 8 8 10 Reference 2014 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circu...

Page 20: ...OM 222166 Page 14 5 4 Connecting 3 Phase Input Power For 460 575 Volt Models 3 8 in Tools Needed 2 1 4 3 6 5 7 10 8 4 9 6 3 input3 2015 01 803 994 D GND PE Earth Ground ...

Page 21: ...Install strain relief of proper size for unit and conductors Route conductors cord through strain relief Tighten strain relief 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source ground ing terminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 L2 And L3 Connect input con...

Page 22: ...OM 222166 Page 16 Input3 2015 01 Ref 804 430 B Tools Needed 5 5 Connecting 3 Phase Input Power For 400 460 Volt IEC And CE Models 3 8 in 1 5 4 2 3 6 7 10 8 4 9 6 3 GND PE Earth Ground ...

Page 23: ...Relief Customer Supplied Install strain relief of proper size for unit and conductors Route conductors cord through strain relief Tighten strain relief 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source ground ing terminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 L2...

Page 24: ...utput Connector Single Liquid Cooled Output Connection Connect liquid cooled output extension cable to Output Connector 1 or Output Connector 2 Connect Protective Plug to remainingOutput Connector Dual Air Cooled Output Connection Connect air cooled output extension cables to Output Connector 1 and Output Connector 2 Extension cables must be the same length 25 ft 7 6 m 50 ft 15 2 m or 75 ft 22 8 m...

Page 25: ...C Contact closure to A completes 24 volts DC contactor control circuit C D E G Remote Output Control Command reference 10 volts DC Control circuit common Input command signal potentiometer wiper or 0 to 10 volts DC Travel sense detect F J Power Source Fault Absence of internal contact closure between F and J signals power source fault to remote con trol device an external power source must be used...

Page 26: ... 2 Thermocouple No 2 TC2 0 10 volt DC signal 0V 50 F 46 C 10V 1500 F 816 C 3 Thermocouple No 3 TC3 0 10 volt DC signal 0V 50 F 46 C 10V 1500 F 816 C 4 Thermocouple No 4 TC4 0 10 volt DC signal 0V 50 F 46 C 10V 1500 F 816 C 5 Signal Common 6 Thermocouple No 5 TC5 0 10 volt DC signal 0V 50 F 46 C 10V 1500 F 816 C 7 Thermocouple No 6 TC6 0 10 volt DC signal 0V 50 F 46 C 10V 1500 F 816 C 8 Unused 9 Un...

Page 27: ...source output if a potentially hazardous condition exists at the heating device connected to the power source e g insulation has broken down on a heating blanket causing the conductor to come into contact with the workpiece or a heating coil touches the workpiece causing a short in the output circuit 1 Receptacles 2 Plug To connect plug align key with key way insert end into receptacle and rotate ...

Page 28: ...eldment to be stress relieved 2 Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due to heat convection or conduction and have additional thermocouples applied 3 Attach a spare thermocouple beside control thermocouples 4 Attach thermocouples to ensure uniformity of temperature in both thin and thick workpieces 5 Physically inspect a...

Page 29: ... six 3 wire bundles of shielded cable S The 3 pin male extension cable plugs into the 3 pin female connector on the front of the power source 804 320 A 1 For temperature control mode the power source must have as a minimum one thermocouple connected to receptacle TC1 If multiple thermocouples are desired either use individual thermocouple plugs or the thermocouple extension cable To connect thermo...

Page 30: ...couple to the pliers at the same time when energizing the Thermocouple Attachment Unit This will cause the thermocouple wire to fuse to the pliers rather than the workpiece 7 Press the end of the wire to the workpiece at ninety degrees to the surface and maintain a firm pressure Make sure the Thermocouple Attach ment Unit is charged and wait for the ready light to glow 8 Press discharge button and...

Page 31: ...contact with the material being heated The tip of the sensor should be positioned under the center of the wires of the blanket anywhere along the blanket length To prevent thermocouple sensor from pulling out of position contact TC sensor securing band 301 073 is available NOTICE When using a contact thermocouple with air cooled blankets position is critical If any part of the blan ket exceeds 400...

Page 32: ...tton Use button to stop a heating process 9 Hold Button Use button to hold a heating process 10 Run Button Use button to run a heating process 11 Cursor Button Use button to move selection cursor in the 4 x 40 LCD display item 18 12 Program Button Use button to program the process control 13 Run Status Button Use button to display real time operating status 14 Parameter Button Use button to displa...

Page 33: ...d cooled or the system will not operate in this case the protective plug is not used When two extension cables and heating devices are utilized on the system the extension cable lengths and heating devices MUST be identical see Section 5 7 The ProHeat 35 is intelligent to the point that it will automatically adjust output power levels if internal system operating parameters or internal tempera tur...

Page 34: ...factory default is 25 F Control Mode Either Temperature Remote or Power vs Time Time or Manual For more details about methods of control see Section 7 5 S The factory default is temperature based control Rolling Inductor Initial kW The factory default is 0 0 Max setting is dependant on Max Output setting Power Output The factory default is 35 kW Rolling Inductor Cooler Purge Time The factory defau...

Page 35: ...ay lights press and hold the Increase and Decrease buttons A message will display Press Program to reset factory defaults Release the Increase and Decrease buttons and press the Program button 7 5 Programming Programmingallows the operator to setup a program for a particular heating process The selections available are Temperature Remote Manual or Power vs Time Time 7 5 1 Temperature Based Control...

Page 36: ...ws the operator to program a temperature and soak time as well as a cooling rate from bake out if desired When this process is selected the following screen appears on the display Mode Bake Out Control TC 1 Soak Temp 600 Soak Time 01 00 00 Cool Temp 200 Cool Rate 600 _ Hr Bake Out Screen The default position of the cursor is next to Control TC Press the Increase or Decrease button to select the nu...

Page 37: ... thermocouple TC2 thru TC4 can be used for controlling or monitoring When a thermocouple is selected as control the LED adjacent to the seven segment display illuminates Use the Cursor button to move the cursor to the desired selection Ramp Temperature Ramp Rate Soak Temperature or Soak Time and press the Increase or Decrease button to change the value to the desired setting Figure 6 1 Soak Parame...

Page 38: ...TC to heat up above the minimum set point tolerance allowing the Soak cycle to continue 2 Manipulate the coil over the hot area allowing that area to cool down To accomplish this you must stop the cycle spread coil turns apart remove coil turns or pull the coil away decoupling the coil only over the area where the hot control TC is located As a result the output power will increase slightly allowi...

Page 39: ... 0 and 100 hours or Extended S End is programmed to indicate the completion of the cycle and termination of output power Step Function When type is set to Step the following screen appears on the display Mode Custom Program Segment 1 Type Step Temperature 600 Custom Program Screen Use the Cursor button to move the cursor to the Temperature position and the initial temperature can be adjusted using...

Page 40: ...only changeable parameter in the End segment is selecting the number of thermocouples Use the Cursor button to move the cursor to the Control TC position Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1 2 3 or 1 2 3 4 TC1 MUST always be a control thermocouple TC2 thru TC4 can be used for controlling or ...

Page 41: ...rees F at a ramp of 600 degrees per hour Mode Custom Program Segment 3 Type Soak Soak Time 01 00 00 Custom Program Screen Soak at 1250 degrees F for a period of 1 hour Mode Custom Program Segment 4 Type Ramp Temperature 600 Ramp Rate 600 _ Hr Custom Program Screen Controlledcooling to 600 degrees F at a rate of 600 degrees per hour Mode Custom Program Segment 5 Type End Control TC 1 Custom Program...

Page 42: ...tem and controls the heating process based on programmed time and power Power increases over a pro grammed amount of time Press the Program button to access the programming mode Use the cursor button to move the cursor between Mode Segment Type Power and Time Mode Timed Segment 1 Type Power Level Power 0 0 KW Time 00 00 00 The default position of the cursor is next to Program Press the Increase or...

Page 43: ...a which can quickly heat a part to over 600 F 315 C if it is not moving fast enough This can damage the inductor or part Using the travel detector the system reduces output as travel speed decreases and disables output when travel stops The travel detector is a sensitive instrument that can measure travel speeds down to one IPM Once the part travel is stopped there is a three second delay before o...

Page 44: ... Rolling Inductor Cooler Purge Time is set to 60 seconds for applications using the 60 foot inductor cables This can be set down to 30 seconds for the standard Rolling Inductor with 30 foot cables The ProHeat automatically doubles the time when two Rolling Inductors are connected Simultaneouslypress the Parameters Hz V A kW and Program buttons a second time and the following screen will appear on ...

Page 45: ...ture based mode Preheat Bake Out PWHT or Custom different style screens appear on the display Run status is for monitoring pur poses only and has no selectable or changeable parameters 7 6 1 Temperature Based Control 7 6 1 1 Preheat Bake Out And PWHT Run Status Screen Mode Preheat TC5 77 Target Temp TC6 77 Countdown TvlIPM Off 0 Status Stopped Run Status Screen Mode displays the programming mode P...

Page 46: ...ce Countdown shows the time remaining of the heating cycle and Status indicates if the system is running or stopped This screen is for monitoring purposes only No changes can be made to the run status screen and the Cursor Increase and Decrease buttons are not functional 7 6 4 Power vs Time Control Mode Power vs Time TC5 OPEN Segment 1 TC6 OPEN Type TvlIPM Off 0 Power 0 0 KW Type End Run Status Sc...

Page 47: ...Screen The Cooler button is inactive when no cooler is detected and no liquid cooled output cable is attached When a Rolling Inductor is connected to the power source the cooler will purge for time set in SYSTEM SETUP1 RI Clr Purge which is typically 30 60 seconds per rolling inductor before allowing output to be enabled 7 9 Real Time Operation Each time the unit is first turned On it initiates a ...

Page 48: ...ue until the end of the program is reached or the Stop button is pressed The system has a hold function that will maintain a temperature or hold the soak time of any active temperature controlled program Pressing the Hold button will only activate the hold function while in the run mode If the system is not in the run mode the following screen will appear on the display Must be running to enter Ho...

Page 49: ...ment of a Custom Program S Use the Cursor button to move the cursor to the parameter that will be changed S Press the Increase or Decrease button to make desired changes S Press the Run button to resume program operation and the yellow indicator LED will illuminate and the Hold button yellow indicator LED will turn off Any program parameter temperatures rates times or number of TC s can be changed...

Page 50: ...tput for continuous operation 700 V 5 25 7 kHz See Note 1 700 V 25 7 30 kHz Single Liquid Cooled 350 A 700 V 5 20 kHz See Note 2 700 V 20 30 kHz Dual Liquid Cooled 350 A per output 700 A total 700 V 5 20 kHz See Note 2 700 V 20 30 kHz Note 1 In the frequency range of 25 7 to 30 KHz the maxi mum output amperage de creases linearly from 250 down to 175 amperes per output Re gardless of frequency aft...

Page 51: ...des output power starting at the RI Init KW value as set in SYSTEM SETUP1 screen at the start of the cycle The curves illustrated increase as shown directly from the RI Init KW value The rate of power output is limited at travel speeds below 15 in min 38cm min or when no travel detection is present to help prevent temperature overshoot in the part With travel detection and travel speeds above 15 i...

Page 52: ...nt Reference Daily 1 2 n Visually inspect condi tion of cords and cables l damaged cords or cables Every 3 Months 1 2 1 2 Section 5 7 5 12 l Damaged or Unreadable Labels Output Connector Con tacts Ground Sense Lead Re ceptacles Operator Interface Over lay 1 2 n Integrity Of Protective Plug Replace If Necessary nlCracked Cables Every 6 Months Section 10 10 Inside Unit Every Year Sections 8 2 8 3 n ...

Page 53: ... corner of display 8 Let unit idle for a minimum of 15 minutes before checking calibration 9 Turn on Fluke 714 Thermocouple Calibrator and Precision DVM Leave them on for a minimum of 15 minutes before checking calibration 10 Verify TC1 and TC2 are set to K Type See Section 7 4 for detailed instructions 8 3 2 TC Input Output Check 1 Connect precision DVM DC Volts set to display in thousandths to R...

Page 54: ...erson disconnect primary power 4 Remove precision DVM and TC calibrator 5 Complete calibration label place it on unit directly above TC1 display I D No TC board serial number Be sure the serial number matches the board in the machine By your initials Date today s date Due date 1 year from today 6 Print a copy of the certificate to send with the ProHeat 35 7 If entering data in a spreadsheet save d...

Page 55: ...ge Equivalent Out V Temp F Out V Temp F Out V Temp F CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 CHANNEL 5 CHANNEL 6 A 232171 C 09 09 16 Serial Number CERTIFICATE OF CALIBRATION Calibration Date 382 F PRIMARY STANDARD 882 F PRIMARY STANDARD PRIMARY STANDARD Company name Company name TCI Serial Number Certified by Thermocouple Calibrator Instrumentation Used maintained by Serial Number 1382 F Calibrate...

Page 56: ...pany name TCI Serial Number Certified by Thermocouple Calibrator Instrumentation Used maintained by Serial Number Calibrated Multimeter Com pany Nam e Street PO Box City State Zip Code Re Calibration Date V o lta g e E q u iv a le n t V o ltag e E q u iv a le n t V o ltag e E q u iva len t O u t V T em p C O u t V T e m p C O u t V T e m p C C H AN N E L 1 C H AN N E L 2 C H AN N E L 3 C H AN N E ...

Page 57: ...d D If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job D When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free D Disconnect input power conductors from deenergized supply line BEFORE moving an induction heating power source SIGNIFICANT DC VOLTAGE exists in inverter power s...

Page 58: ... RADIATION can cause interference D High frequency H F can interfere with radio navigation safety services computers and communicationsequipment D Have only qualified persons familiar with electronic equipment install test and service H F producing units D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If not...

Page 59: ...shootingcapability consists of the Fault LED Limit LED and message screens that appear on the front panel LCD display 10 1 Operator Interface Indicators 1 Fault LED LED lights to indicate a system fault condition 2 Limit LED LED lights to indicate a system limit condition 3 4 x 40 LCD Display Displays programming run status param eters fault and limit conditions and troubleshootingguide 803 995 B ...

Page 60: ...ondition press the Run Status button and the LCD display will show a message describing the new and previous limit messages To obtain additional information regarding the limit condition and suggested solutions to resolve the limit press the Increase button and the LCD display will indicate possible solutions based on the type of limit condition If the operator determines that the best course of a...

Page 61: ...Pressing the Decrease button will acknowledge the fault and the red Fault LED will stop flashing and remain on continuously However the Stop button LED will continue to flash indicating that the process has stopped To obtain additional information regarding the fault condition and suggested solutions to resolve the fault press the Increase button and the LCD display will indicate possible solution...

Page 62: ... 1 and cable 2 identification on diagnostic screen DIAG1 see Section 10 7 Rolling Inductor only Verify TC5 TC6 connection F69 Coolant Overtemp Fault Check coolant flow and level Clean coolant filters and heat exchanger Increase number of turns Verify appropriate insulation thickness F70 Internal Communication Fault Service required F71 Internal Thermistor Fault Service required F72 Coolant Thermis...

Page 63: ...replace if neces sary Verify infrared sensor is working correctly replace if necessary If thermocouple measuring device is connected verify continuity of exten sion cable and measuring device replace if necessary 10 7 System Diagnostic Screens Additionalsystem diagnostics are available and accessible through the operator interface Detail operational parameters can be accessed by pressing and holdi...

Page 64: ...rm2 75 Therm5 OPEN VLnC A 460V Therm3 75 ClrTmp 77 VBus 650V Therm4 OPEN System Diagnostic Screen VLnA B This is the phase to phase line voltage between phases A and B VLnB C This is the phase to phase line voltage between phases B and C VLnC A This is the phase to phase line voltage between phases C and A VBus This is the DC bus voltage Therm1 This is the temperature of the current source primary...

Page 65: ...Inductor PC1 Bridge Control uP 1 21 1 24 269940 8 19 2015 907271 MF320172G MG180044G PC2 Operator Interface 1 29 Currently 1 30 274028 Added IR Sensor Control 907432 MF320172G MF340141G PC1 Bridge Control uP 1 25 Currently 1 27 273113 The Bridge Control PLD is 1 28 and has not changed since the ProHeat 35 was released If possible verify firmware revision levels prior to ordering circuit boards If ...

Page 66: ...us terminal on PC4 as shown until voltage drops to near 0 zero volts If the capacitor voltage does not drop to near zero after several minutes use a bleeder resistor of between 200 and 500 ohms at least 10 watts and 16 AWG 600 volts ac in sulation rated wire to discharge the capacitor s 3 Typical Bleeder Resistor An example of a typical bleeder resistor is shown on this page Proceed with job insid...

Page 67: ...put capacitors are discharged Blow out inside of unit Blow out fan motors in right side panel and front panel 804 625 B Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 68: ...OM 222166 Page 62 SECTION 11 ELECTRICAL DIAGRAM Figure 11 1 Circuit Diagram ...

Page 69: ...OM 222166 Page 63 218 057 M ...

Page 70: ...e Cont Polyolefin Copolymer 1 8 222106 Bracket Mtg Fan 1 9 FM3 236263 Fan Muffin 24vdc 3000 Rpm 130 CFM 1 10 206270 Insulator Side RH 2 11 197900 Cable Work Ground Includes 1 12 271878 Handle 1 13 271466 Grip Handle 1 14 271842 Magnet Permanent 1 15 127836 Plug Tw Lk Insul Male 1 RC2 135635 Housing Plug Pins Service Kit 1 PLG2 131054 Housing Rcpt Skts Service Kit 1 PLG61 131204 Housing Plug Skts S...

Page 71: ...600vac Scr Term Wide Tgl 1 7 252731 Label Warning Read Labels On Off Storage Temp 1 8 221493 Label TC 1 6 1 9 115440 Standoff No 6 32 14 10 224143 Gasket Meter Lens 1 11 PC10 239271 Circuit Card Assy Display 1 12 PC2 274028 Circuit Card Assy Operator Interface W Program 1 PLG24 115091 Housing Plug Skts Service Kit 1 13 247615 Gasket Operator Interface Proheat 1 14 246430 Deflector 1 15 203310 Insu...

Page 72: ...50 1 9 RC14 143976 Rcpt W Skts Service Kit 1 10 RC9 047637 Housing Plug Pins Service Kit 1 11 224989 Receptacle Assy Output With Leads 2 234531 Shell W Contact Pin And Socket Service Kit For 224 989 0 12 224042 Connector Circ Cpc Protective Cap 1 13 170391 Connector Circ Ms Protective Cap 1 14 147195 Nut 375 27 54 Hex 25 H Nyl 1 RC21 22 135635 Housing Plug Pins Service Kit 2 PLG21 22 131054 Housin...

Page 73: ... C1 2 213870 Capacitor Elctlt 2 7 T1 213583 Transformer HF 1 7 T1 227065 Transformer Hf 400v Model 1 8 216629 Bracket Fan 1 9 FM1 FM2 224694 Fan Muffin 24 V 2 10 RC4 115090 Housing Plug Pins Service Kit 1 11 217992 Baffle Air Bottom 1 12 224973 Insulator Lift Frame 2 13 603115 Weatherstripping 2 14 026627 Gasket Lifting Eye Cover 1 PLG4 115094 Housing Plug Skts Service Kit 1 15 226837 Washer Rubbe...

Page 74: ...r Tooth 377 ID X 0 507 OD X 022t Stl Pld 2 7 098691 Stand Off No 6 32 X 500 Lg 250 Hex Stl M F 6 8 217326 Bracket TC Interface 1 9 250975 Insulator Tank Cap 1 229382 Support Leads Bridge Output 1 10 PC5 239257 Kit Circuit Card Assy Intrcnct Bridge 1 11 PC3 239236 Circuit Card Assy Tc Interface 1 12 208591 Screw M 5 8 x 12 Soc Hd Torx Stl Pld Sems 12 13 212038 Screw M4 7 X 8 5 Pan Hd Phl Stl Pld 8 ...

Page 75: ...ts Service Kit 1 PLG33 38 54 131204 Housing Plug Skts Service Kit 7 PLG51 57 11 5093 Housing Plug Skts Service Kit 2 PLG58 115094 Housing Plug Skts Service Kit 1 23 L3 227082 Choke Common Mode 400 V Model Only 1 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 dist...

Page 76: ...g Hole 1 5 223120 Block Term 115 Amp 3 Pole Screw Term 1 6 115443 Stand Off No 6 32 X 750 Lg 250 Hex 5 7 145743 Lug Univ W Scr 600V 2 14 Wire 250 Stud 1 8 RT1 222326 Thermistor NTC 30 K Ohm At 25 Deg C 34 In Lead 1 9 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 2 10 224391 Panel Insulating Mtg Capacitor 1 11 605339 Washer Tooth 377 ID X 0 507 OD X 022t Stl Pld 2 12 PC4 239240 Kit Circuit ...

Page 77: ...10 411 115093 Housing Plug Skts Service Kit 3 PLG47 115091 Housing Plug Skts Service Kit 1 PLG45 61 131204 Housing Plug Skts Service Kit 2 PLG62 201665 Housing Plug Skts Service Kit 1 PLG63 115094 Housing Plug Skts Service Kit 1 PLG111 112 121 132 141 142 131054 Housing Rcpt Skts Service Kit 6 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacem...

Page 78: ...1 312 ID X 1 500 Mtg Hole 1 5 PC9 239284 Circuit Card Assy Input Filter 1 6 115443 Stand Off No 6 32 X 750 Lg 250 Hex 5 7 148743 Lug Univ W Scr 600v 2 14 Wire 250 Stud 1 8 RT1 222326 Thermistor NTC 30 K Ohm At 25 Deg C 34 In Lead 1 9 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 6 10 224391 Panel Insulating Mtg Capacitor 1 11 605339 Washer Tooth 377 ID X 0 507 OD X 022t Stl Pld 2 12 PC4 23...

Page 79: ... 000 Mtg Hole 1 22 245842 Assy Resistor 1 PLG64 410 411 115093 Housing Plug Skts Service Kit 3 PLG47 115091 Housing Plug Skts Service Kit 1 PLG45 61 131204 Housing Plug Skts Service Kit 2 PLG62 201665 Housing Plug Skts Service Kit 1 PLG63 115094 Housing Plug Skts Service Kit 1 PLG111 112 121 132 141 142 131054 Housing Rcpt Skts Service Kit 6 To maintain the factory original performance of your equ...

Page 80: ...Off No 6 32 X 750 Lg 250 Hex 7 6 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 2 7 RT3 222327 Thermistor Ntc 30 K Ohm At 25 Deg C 24 In Lead 1 8 030170 Bushing Snap In Nyl 750 Id X 1 000 Mtg Hole 1 9 218430 Cover Access 1 10 220825 Bus Bar Capacitor 4 11 C7 C10 218687 Capacitor Polyp Film 1 35 UF 700 Vac 5 0 4 11 C7 C10 225775 Capacitor Polyp Film 1 10 UF 700 Vac 5 0 400 V Model Only 4 12 ...

Page 81: ...vice Kit 2 PLG77 119 115092 Housing Plug Skts Service Kit 2 PLG17 115091 Housing Plug Skts Service Kit 1 PLG18 116 131056 Housing Rcpt Skts Service Kit 2 PLG13 113 162382 Housing Plug Skts Service Kit 2 PLG14 130203 Housing Plug Skts Service Kit 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when...

Page 82: ... Cs 2 2 252628 Socket 14mm Blank Plug 1 3 221099 Clamp Strain Relief 2 4 136343 Screw K50 X 20 Pan Hd Phl Stl Pld Pt 2 5 224261 Cap Plug Assy 1 6 254886 Collar Coupling 1 7 254885 Retainer Contact 1 8 252627 Pin 14mm Blank Plug 1 9 253842 Shell Assy Connector Protective Plug 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model a...

Page 83: ...221099 Clamp Strain Relief 2 4 136343 Screw K50 x 20 Pan Hd Phl Stl Pld Pt Thread Forming 2 5 254887 Shell Connector Cable Female With Seal 2 6 224259 Clamp Strain Relief Socket 4 7 228296 Screw Ka35x10 Pan Hd Phl Sst Pln Pt Thread Forming 4 8 197635 Label Warning Flexible Induction Cords 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement...

Page 84: ...54886 Coupling Collar 1 3 221099 Strain Relief Clamp 2 4 136343 Screw K50 X 20 2 5 210912 Protective Cap 4 6 204954 Quick Connect Fitting 4 7 254889 Connector Shell 2 8 254890 Coupling Collar 2 9 224258 Strain Relief Pin Clamp 4 10 228296 Screw Ka35x10 4 11 197635 Warning Label 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Mode...

Page 85: ...049 Quantity 1 254887 Connector Shell 2 2 204954 Plastic Fitting 2 3 210912 Protective Cap 2 4 224259 Strain Relief Clamp 4 5 228296 Screw Ka35x10 4 6 197635 Warning Label 2 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 ...

Page 86: ... Quantity 1 204955 Ftg Plstc Coupler Qdisc X 1 4 Npt Female 2 227601 Hose Assy Coolant Series Adapt 24in Quick To Quick 201430 Hose Assy Coolant 36 In Lh Thread To Quick Connect 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 ...

Page 87: ...Sst2s Mp 2 5 228296 Screw Ka35 X 10 Pan Hd Phl Sst Pln Pt Thread Forming 4 6 254889 Shell Connector Cable Male 2 7 254890 Collar Coupling 2 8 224145 Pin Radsok 14mm Cable End 2 9 224258 Clamp Strain Relief Pin 4 10 196965 Wearplate Induction Blanket 6 125 in wide 1 10 259960 Wearplate Induction Blanket 5 000 in wide 1 11 197866 Strap Replacement 1 12 195337 Induction Blanket Sleeve 13 7 64 In 229 ...

Page 88: ...3 Induction Blanket Sleeve 7 1 2 In 191 mm Wide 133 In 3378 mm Long 38 In 965 mm Dia Pipe 1 12 194814 Induction Blanket Sleeve 7 1 2 In 191 mm Wide 140 In 3556 mm Long 40 In 1016 mm Dia Pipe 1 12 198669 Induction Blanket Sleeve 7 1 2 In 191 mm Wide 146 In 3708 mm Long 42 In 1067 mm Dia Pipe 1 12 194810 Induction Blanket Sleeve 7 1 2 In 191 mm Wide 153 In 3886 mm Long 44 In 1118 mm Dia Pipe 1 12 19...

Page 89: ... Bearing 4 3 263696 Washer Thrust 4 4 263530 Wheel Rolling Inductor 4 5 265978 Bracket Travel Sensor Mtg Rails 2 6 263213 Bracket Mtg Temperature Feedback 2 7 262268 Plate Top W Coating 1 8 262166 Handle Plastic Rolling Inductor 2 9 263854 Bracket Rolling Inductor Strain Relief Cover 1 10 263690 Spacer Glass Polyester 1 11 204954 Ftg Plstc Nipple Qdisc X 1 4 Npt Female 2 12 210912 Cap Protective R...

Page 90: ...ulation Bottom 1 20 262194 Wearplate Mica 1 21 262172 Handle Assy Arm 1 22 259455 Spacer Hinge 2 23 263732 Hinge Spring 1 24 263697 Extrusion W Rivnuts 2 25 262173 Insert Extrusion Channel 2 26 262183 Insulation Top 1 27 263986 Spacer Hinge 1 263854 Bracket Mtg IR Connector 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model an...

Page 91: ...Arm 2 3 263533 Assy Swivel Shaft Induction Arm 1 4 264044 Screw Thumb Sst 10 32 X 1 00 Knurled 2 5 263528 Housing Swivel Induction Arm 1 6 261778 Hinge Spring Induction Arm 1 7 263534 Assy Induction Arm Attachment Welded 1 8 124778 Knob T 2 000 Bar W 312 18 Stud 1 000 Lg 1 9 259968 Bolt Eye Shld Thd Stem 375 16 X 1 500 Fbrgls 1 To maintain the factory original performance of your equipment use onl...

Page 92: ... Label Warning Rolling Inductor Stand 1 8 269159 Tube Assy Middle Welded Rolling Inductor Stand 1 9 269678 Clip C 500ID X 938OD X 150THK Nylon w tab 2 10 269406 Assy Head Rolling Inductor Stand Includes 1 11 192362 Bracket Mtg Nyl 1 2 Conduit 2 12 269448 Stand Off No 10 32 X 250 Lg 375 Hex SST 2 13 269171 Foot Push Rivet 59ODX 35H 04 08THK 165 Mtg Blk 4 14 269170 Spring Rolling Inductor Stand 4 15...

Page 93: ...Stls 1 6 262553 Knob Threaded Three Arm Phenolic 1 7 266751 Spacer AL 250 ID X 500 OD X 1 00 LG 1 8 266223 Clamp Travel Sensor Pivot Assembly 1 9 264069 Sensor Travel Assembly 1 10 265988 Shaft Force Adjustment 1 11 266225 Spring Cprsn 360 OD X 041 Wire X 750 Free Stn 1 266215 Cable Extension Travel Sensor Not Shown 1 141162 Housing Plug Pins Service Kit 14 18 GA 1 152568 Housing Plug Skts Service...

Page 94: ...265083 Washer Flat 812idx1 375odx 062t Stnls Stl 1 7 265084 Collar IR Temperature Sensor Upper 1 8 265085 Collar IR Temperature Sensor Lower 1 9 263855 Ftg Brs Elbow Qdisc 1 8 Npt X 250 Tbg Swivl 1 10 265116 Tubing Pneumatic V 0 250 Od X 170 ID 3 50 in 11 265117 Tubing Gl Acryl 258 278 Id Blk 3 0 in 12 264070 Ftg Air Bulkhead Panel Mtg Qdisc 1 4 Npt X 250tbg 1 13 267465 Ftg Brs Elbow Qdisc 1 4 Npt...

Page 95: ...ure TC Connection With Rivet Nuts Includes 1 263831 Enclosure TC Connection 1 267916 Gasket Epfm 3 500 X 250 X 125 Thk W Psa 1 221493 Label TC1 6 1 260811 Nut 010 32 Hex Stl Pld Insert 0 6 197063 Plug Thermocouple Type K Panel Mount 6 7 246958 Core Ferrite 25 90mm Od X 12 80mm Id X 28 60mm Lg 1 8 134735 Conn Circ Ms Cpc 14skt Size 20 Rcpt Panel Pushin 1 9 266220 Cable Pigtail W 14 Pin Male 1 To ma...

Page 96: ...1 3 265148 Coupler Air Regulator Filter 1 4 204005 Ftg Plstc Brs Elbow Qdisc 1 4 Npt X 250 Tbg Swivl 1 5 176518 Ftg Pipe Brs Elbow St 1 4 Npt 1 6 265155 Bracket Mtg Air Regulator Filter 1 7 265075 Bracket Cover Air Regulator 1 8 265075 Bracket Cover air Regulator 1 227877 Filter Air Element Not Shown 0 264232 Filter Oil Separator Not Shown 0 Recommended Spare Parts To maintain the factory original...

Page 97: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 98: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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