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OM-222 166 Page 41

SECTION 9

−

DIAGNOSTICS & TROUBLESHOOTING

The ProHeat 35 power source has on-board capabilities to aid in troubleshooting problems should any conditions occur during operation. This

troubleshooting capability consists of the Fault LED, Limit LED, and message screens that appear on the front panel LCD display.

9-1. Operator 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

troubleshooting guide.

803 995-B

3

2

1

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Содержание ProHeat 35

Страница 1: ...ProHeat 35 Processes Description Induction Heating Power Source Induction Heating OM 222 166K 2007 11 File Induction Heating Visit our website at www MillerWelds com...

Страница 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...

Страница 3: ...ifications 10 4 2 Selecting A Location 11 4 3 Tipping 11 4 4 Electrical Service Guide 12 4 5 Connecting 3 Phase Input Power For 460 575 Volt Models 13 4 6 Connecting 3 Phase Input Power For 400 460 Vo...

Страница 4: ...Blowing Out Inside Of Unit 38 SECTION 8 SAFETY PRECAUTIONS FOR SERVICING 39 8 1 Symbol Usage 39 8 2 Servicing Hazards 39 8 3 California Proposition 65 Warnings 40 8 4 EMF Information 40 SECTION 9 DIAG...

Страница 5: ...9 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 Compatibili...

Страница 6: ......

Страница 7: ...47 see Safety Standards D Use only nonconductive coolant hoses with a minimum length of 18 inches 457 mm to provide isolation D Properly install and ground this equipment according to its Owner s Manu...

Страница 8: ...acturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations OVERUSE can cause OVERHEATING D Allow cooling period D Reduce output or reduce duty cycle...

Страница 9: ...netic 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 Magnetic Fields Backgr...

Страница 10: ...ns les conditions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position co...

Страница 11: ...pe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter LE CHAUFFAGE PAR INDUCTION peut provoquer des br lures D Des pi ces ou de l quipement chaud peuvent provoquer des blessures D N...

Страница 12: ...h PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov National Electrical Code NFPA Standard 70 de Natio...

Страница 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...

Страница 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...

Страница 15: ...EEE Label For Products Sold Within The EU Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated colle...

Страница 16: ...Consumption Three Phase Percent Remote Panel Local High Temperature Voltage Input Off On SECTION 4 INSTALLATION 4 1 Specifications Output Frequency Rated Output Required Reflective Inductance Amperes...

Страница 17: ...oor 4 Plate Label CE Models Only Label located under power switch 5 Rating Label CE Models Only Use rating label to determine input power needs 6 Line Disconnect Device Locate unit near correct input...

Страница 18: ...ded Input Conductor Length In Feet Meters 254 77 214 65 334 102 Min Grounding Conductor Size In AWG 4 8 8 10 Reference 2005 National Electrical Code NEC including article 630 1 If a circuit breaker is...

Страница 19: ...ity 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 Yel...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 25: ...should be located in the hottest portion of the weldment to be stress relieved 2 Consider all nozzles and other welded attachments that cause potential heat sinks through metal mass or cold spots due...

Страница 26: ...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 m...

Страница 27: ...ermocouple 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...

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

Страница 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...

Страница 30: ...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 outpu...

Страница 31: ...tory default is On Input Type press the Increase or Decrease button to select the desired temperature input device S The factory default and only selection is K TC Control Mode press the Increase or D...

Страница 32: ...cess is a simple method of heating material to a desired temperature and holding that temperature for a specific period of time When this process is selected the following screen will appear on the LC...

Страница 33: ...ak Time Cool Temperature or Cool Rate and press the Increase or Decrease button to change the value to the desired setting The minimum and maximum soak temperature settings for bake out are 0 and 1000...

Страница 34: ...and 1450 F 18 and 788 C The minimum and maximum ramp rates are 10 and 9999 F hr 6 and 5555 C hr The minimum and maximum soak temperatures are 0 and 1450 F 18 and 788 C The minimum and maximum soak tim...

Страница 35: ...imum temperature of 1450 F 788 C can be programmed S Ramp increases or decreases the temperature in the part at a controlled rate in degrees per hour A maximum temperature of 1450 F 788 C and a maximu...

Страница 36: ...gram Screen Use the Cursor button to move the cursor to the Temperature or Ramp Rate position and use the Increase or Decrease button to set the desired value When the cursor is in the Ramp Rate posit...

Страница 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 button to select...

Страница 38: ...1 00 00 Custom Program Screen Soak at 1250 degrees F for a period of 1 00 Mode Custom Program Segment 4 Type Ramp Temperature 600 Ramp Rate 600 _ Hr Custom Program Screen Controlledcooling to 600 degr...

Страница 39: ...PWHT or Custom different style screens appear on the display Run status is for monitoring purposes only and has no selectable or changeable parameters 6 5 1 Temperature Based Control 6 5 1 1 Preheat B...

Страница 40: ...dition temperatures of thermocouples TC5 and TC6 are also displayed The Parameters screen is for monitoring purposes only and has no selectable or changeable parameters Power 0 0 KW TC5 77 Current 0 A...

Страница 41: ...om the TC s thermocouples If no thermocouples are connected the displays indicate OPEN S Control LED s illuminate to indicate the number of control TC s in the last program S The appropriate degree un...

Страница 42: ...LED will illuminate and the Run button yellow indicator LED will turn off When in hold the system will maintain the actual temperature of the hottest thermocouple while the program is being changed S...

Страница 43: ...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...

Страница 44: ...k Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months 1 2 1 2 Section 4 7 4 12 l Damaged or Unreadable Labels Output Connector Con tacts Ground Sense Lead...

Страница 45: ...e 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 V...

Страница 46: ...Code Section 25249 5 et seq 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 reprod...

Страница 47: ...hootingcapability 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 fault...

Страница 48: ...the limit condition 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 a...

Страница 49: ...as 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 solutions ba...

Страница 50: ...diagnostics are available and accessible through the operator interface Detail operational parameters can be accessed by pressing and holding the Run Status button and pressing the Parameters Hz V A...

Страница 51: ...se 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...

Страница 52: ...ct fan motor FM3 1 Current Source Interconnect Board PC4 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC4 as shown until voltage drops to near 0 zero volts If the cap...

Страница 53: ...t 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...

Страница 54: ...OM 222 166 Page 48 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram...

Страница 55: ...OM 222 166 Page 49 218 057 G...

Страница 56: ...copolymer 1 9 222 106 BRACKET mtg fan 1 10 FM3 236 263 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...

Страница 57: ...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...

Страница 58: ...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 with leads 2 234 531 SHELL w contact pin and socket service kit for 224 989...

Страница 59: ...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...

Страница 60: ...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...

Страница 61: ...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...

Страница 62: ...BLOCK term 115 amp 3 pole screw term 1 6 115 443 STAND OFF no 6 32 x 750 lg 250 hex 5 7 148 743 LUG univ w scr 600V 2 14 wire 250 stud 1 8 RT1 222 326 THERMISTOR ntc 30 k ohm at 25 deg C 34 in lead 1...

Страница 63: ...UG SKTS SERVICE KIT 3 PLG47 115 091 HOUSING PLUG SKTS SERVICE KIT 1 PLG45 61 131 204 HOUSING PLUG SKTS SERVICE KIT 2 PLG62 201 665 HOUSING PLUG SKTS SERVICE KIT 1 PLG63 115 094 HOUSING PLUG SKTS SERVI...

Страница 64: ...ARD ASSY input filter 1 6 115 443 STAND OFF no 6 32 x 750 lg 250 hex 5 7 148 743 LUG univ w scr 600V 2 14 wire 250 stud 1 8 RT1 222 326 THERMISTOR ntc 30 k ohm at 25 deg C 34 in lead 1 9 083 147 GROMM...

Страница 65: ...93 HOUSING PLUG SKTS SERVICE KIT 3 PLG47 115 091 HOUSING PLUG SKTS SERVICE KIT 1 PLG45 61 131 204 HOUSING PLUG SKTS SERVICE KIT 2 PLG62 201 665 HOUSING PLUG SKTS SERVICE KIT 1 PLG63 115 094 HOUSING PL...

Страница 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...

Страница 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...

Страница 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...

Страница 69: ...362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in...

Страница 70: ...OM 222 166 Page 64 Notes...

Страница 71: ...nduction 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...

Страница 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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