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Miller ProHeat 35 OM-222 166F, Owner'S Manual

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ProHeat 35

Processes

Description

Induction Heating Power Source

Induction Heating

OM-222 166

F

2006

−

05

File: Induction Heating

Visit our website at

www.MillerWelds.com

Summary of Contents for ProHeat 35 OM-222 166F

Page 1: ...ProHeat 35 Processes Description Induction Heating Power Source Induction Heating OM 222 166F 2006 05 File Induction Heating Visit our website at www MillerWelds com...

Page 2: ...tinue 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...

Page 3: ...Input Power For 400 460 Volt Models 14 4 7 Power Source Output Connections 15 4 8 Remote 14 Receptacle RC14 Information and Connections 16 4 9 Remote 14 Socket Information 16 4 10 Temperature Recorde...

Page 4: ...Symbols for Installation Operation and Maintenance 41 8 4 Principal Safety Standards 41 8 5 California Proposition 65 Warnings 41 8 6 EMF Information 41 SECTION 9 DIAGNOSTICS TROUBLESHOOTING 42 9 1 Op...

Page 5: ...39 02 98290203 European Contact Signature Declares that this product ProHeat 35 conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic compatibi...

Page 6: ......

Page 7: ...mum length of 18 inches 457 mm to provide isolation D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground ch...

Page 8: ...ed person familiar with electronic equipment per form this installation D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the instal...

Page 9: ...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 m...

Page 10: ...orrectement la terre conform ment au manuel utilisateur et aux codes nationaux gouvernementauxet locaux 8 V rifier souvent la terre de l alimentation contr ler et s assurer que le conducteur de terre...

Page 11: ...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 lu...

Page 12: ...nclusions d finitives en ce qui concerne les probl mes de risque possible ou de proposer des recommandations scientifiques claires pour des strat gies suivre en vue de minimiser ou de pr venir des ris...

Page 13: ...sives 3 1 Keep flammables away from heating operation Do not heat near flammables 3 2 Heating sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 4 Breathing...

Page 14: ...d the instructions before working on the machine 6 Connect green or green yellow grounding conductor to ground terminal 7 Connect input conductors L1 L2 And L3 to line terminals 194 466 1 2 4 5 3 6 7...

Page 15: ...nt 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...

Page 16: ...ength 36 3 4 in 993 mm Width 21 1 2 in 546 mm Height 29 in 737 mm 227 lb 103 kg While idling WARNING HIGH FREQUENCY RADIATION can interfere with radio navigation safety services computers and communic...

Page 17: ...r needs Label located under front access door 4 Plate Label CE Models Only Label located under power switch 5 Rating Label CE Models Only Use rating label to determine input power needs 6 Line Disconn...

Page 18: ...ose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to a...

Page 19: ...apacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green...

Page 20: ...ity and correct hole size Welding Power Source Input Power Con nections 2 Strain Relief Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yel...

Page 21: ...Connector 2 Connect Protective Plug to remainingOutput Connector Single Liquid Cooled Output Connection Connect liquid cooled output extension cable to Output Connector 1 or Output Connector 2 Connec...

Page 22: ...to A completes 24 volts dc contactor control circuit C Command reference 10 volts dc D Remote Output Control Control circuit common E Remote Output Control Input command signal potentiometer wiper or...

Page 23: ...ermocouple No 1 TC1 0 10 volt dc signal 0V 50 F 46 C 10V 1500 F 816 C 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...

Page 24: ...ouches the workpiece causing a short in the output circuit The supplied ground lead s must be connected between the workpiece and power source to provide proper secondary insula tion protection from a...

Page 25: ...l thermocouple is placed at the top of the pipe in a standard pipe joint configuration In other applications the thermocouple should be located in the hottest portion of the weldment to be stress reli...

Page 26: ...n female connectors The pin size locates the position of the 2 pin connector on the extension S The extension cable contains six 3 wire bundles of shielded cable S The 3 pin male extension cable plugs...

Page 27: ...he thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit This will cause the thermocouple wire to fuse to the pliers rather than the workpiece 7 Press the end of...

Page 28: ...xtension cable or a Type K 25 ft armored extension cable can be used One of these extensions is required for each sensor In preheating applications the thermocouple must be placed under the induction...

Page 29: ...Button Use button to stop a heating process 9 Hold Button Use button to hold a heating process 10 Run Button Use button to run a heating process 11 Cursor Button Use button to move selection cursor in...

Page 30: ...wo output extension cables If a single output extension cable is used a protective plug provided with the system MUST be placed on the unused output connector or the system will not operate If two out...

Page 31: ...ecrease button to turn LCD display backlight On or Off S The factory default is On Input Type press the Increase or Decrease button to select the desired temperature input device S The factory default...

Page 32: ...sses available as follows Preheat Bakeout PWHT Post Weld Heat Treat and Custom Program Press the Program button to access the programming mode Use the cursor button to move the cursor to the desired t...

Page 33: ...e default position of the cursor is next to Control TC Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are as follows 1 1 2 1...

Page 34: ...00 PWHT Screen The default position of the cursor is next to Control TC Press the Increase or Decrease button to select the number of control thermocouples to be used for the program Selections are a...

Page 35: ...cooling rates and temperatures are different When this process is selected the following screen appears on the display This is the screen for initial use of the system Subsequent use of custom program...

Page 36: ...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 the Increase or Decrease button Pressing t...

Page 37: ...nly 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 but ton to selec...

Page 38: ...grees 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 00 Mode Custom Program Segment 4 Typ...

Page 39: ...ttons A message will display Press Program to reset factory defaults Release the Increase and De crease buttons and press the Program button 6 5 Run Status Run status allows the operator to check stat...

Page 40: ...the system is running or stopped TC5 and TC6 display the temperature of thermocouples 5 and 6 This screen is for monitoring purposes only No changes can be made to the run status screen and the Curso...

Page 41: ...een circuit boards and checking for output isolation faults During this check routine all displays and LED s illuminate and the following screen appears on the display ProHeat Firmware Revision X XX C...

Page 42: ...ontrolled 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 runni...

Page 43: ...gment 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 res...

Page 44: ...peration 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 Single Liquid Cooled See Note 2 700 V 20 30 kHz Dual Liquid Cooled 350 A per output 700 A total 700 V 5...

Page 45: ...Damaged Or Unreadable Labels 1 2 1 2 Repair Or Replace Cracked Cables And Cords Clean Operator Interface Overlay Check Integrity Of Protective Plug Replace If Necessary 1 2 6 Months Blow Out Or Vacuu...

Page 46: ...immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not drape cables over your body D Do not touch p...

Page 47: ...ices For Occupation And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 8 5 California Proposition 65 Warnings Y Wel...

Page 48: ...hooting capability consists of the Fault LED Limit LED and message screens that appear on the front panel LCD display 9 1 Operator Interface Indicators 1 Fault LED LED lights to indicate a system faul...

Page 49: ...A kW button is pressed If a new limit condition should occur after the first is acknowledged the yellow Limit LED will start flashing to indicate a new problem To display the limit condition press th...

Page 50: ...ault LED flashes and the Stop button LED flashes If the active screen on the LCD display is Run Status or Parameters a message describing the particular fault condition will appear on the display If t...

Page 51: ...t connection Verify all output cables are same type Verify receptacle plug connected F69 Coolant Overtemp Fault Check coolant flow and level Clean coolant filters and heat exchanger Increase number of...

Page 52: ...sible labels S AIR for an air cooled cable S LQD for a liquid cooled cable S PLUG for a protective plug S OPEN no cable or plug in place Cable 2 This is the cable type hooked up to output number two P...

Page 53: ...erature of the current source primary heatsink Therm2 This is the temperature of the bridge heatsink Therm3 This the the temperature of the current source secondary heatsink Therm4 Open not used Therm...

Page 54: ...fter 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 exam...

Page 55: ...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 THICKN...

Page 56: ...OM 222 166 Page 50 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram...

Page 57: ...OM 222 166 Page 51 218 057 F...

Page 58: ...copolymer 1 9 222 106 BRACKET mtg fan 1 10 FM3 196 887 FAN muffin 24VDC 3000 RPM 130 CFM 1 11 206 270 INSULATOR side RH 2 12 198 035 HANDLE 1 13 197 931 MAGNET permanent 1 14 197 900 CABLE work groun...

Page 59: ...le 1 6 S1 213 060 SWITCH tgl 3pst 60 A 600 VAC 1 7 212 810 LABEL on off w symbols 1 8 221 493 LABEL TC 1 6 1 9 115 440 STANDOFF no 6 32 14 10 224 143 GASKET meter lens 1 11 PC8 216 068 CIRCUIT CARD AS...

Page 60: ...8 010 467 CONNECTOR clamp cable 1 250 1 9 RC14 143 976 RCPT W SKTS service kit 1 10 RC9 047 636 HOUSING PLUG PINS service kit 1 11 224 989 RECEPTACLE ASSY output 2 12 224 042 CONNECTOR circ CPC protec...

Page 61: ...ANSFORMER hf 1 7 T1 227 065 TRANSFORMER hf 400V model 1 8 216 629 BRACKET fan 1 9 FM1 FM2 222 728 FAN nuffin 48 V 2 10 RC4 115 090 HOUSING PLUG PINS service kit 1 11 217 992 BAFFLE air bottom 1 12 224...

Page 62: ...rface 1 9 218 691 INSULATOR tank cap 1 10 PC5 225 556 KIT circuit card assy intrcnct bridge 1 11 PC3 216 207 CIRCUIT CARD ASSY TC interface 1 12 208 591 SCREW M 5 8X 12 soc hd torx stl pld sems 12 13...

Page 63: ...pyp met film 1 5 uf 700 VAC 4 2 218 688 BUS BAR tank 2 3 221 419 SCREW M8 1 2 x 12 soc hd zinc cls 40 4 602 211 WASHER lock 318 ID X 0 586 OD X 078T STL PLD SPLIT 312 40 Recommended Spare Parts Torque...

Page 64: ...PANEL insulating mtg capacitor 1 11 605 339 WASHER TOOTH 377 ID X 0 507 OD X 022T stl pld 2 12 PC4 228 407 KIT circuit card assy intrcnct I srce inpt 1 13 212 038 SCREW M4 7 x 8 5 pan hd phl stl pld 2...

Page 65: ...capacitor 1 11 605 339 WASHER TOOTH 377 ID X 0 507 OD X 022T stl pld 2 12 PC4 228 407 KIT circuit card assy intrcnct I srce inpt 1 13 212 038 SCREW M4 7 x 8 5 pan hd phl stl pld 2 14 226 579 SPACER l...

Page 66: ...no 6 32 x 750 lg 250 hex 7 6 083 147 GROMMET scr no 8 10 panel hole 312 sq 500 high 2 7 RT3 222 327 THERMISTOR ntc 30 k ohm at 25 deg C 24 in lead 1 8 030 170 BUSHING snap in nyl 750 ID x 1 000 mtg ho...

Page 67: ...G77 119 115 092 HOUSING PLUG SKTS SERVICE KIT 2 PLG17 115 091 HOUSING PLUG SKTS SERVICE KIT 1 PLG18 116 131 056 HOUSING RCPT SKTS SERVICE KIT 2 PLG13 113 162 382 HOUSING PLUG SKTS SERVICE KIT 2 PLG14...

Page 68: ...Item No Figure 11 10 Hermaphroditic Blank Plug Assy 1 221 440 O RING 737 ID x 103 CS 2 2 221 443 SOCKET ASSY radsok 14 mm cable end 1 3 221 099 CLAMP strain relief 2 4 136 343 SCREW K50 x 20 pan hd ph...

Page 69: ...Notes...

Page 70: ...Notes...

Page 71: ...Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s...

Page 72: ...retain with 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...

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