Instruction/ maintenance manual of the product ProHeat 35 Miller Electric
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ProHeat 35 Processes Description Induction Heating Power Source Induction Heating OM-222 166K 2007 − 11 File: Induction Heating V isit our website at www.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS 6-5. Run Status 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1. T emperature Based Control 33 . . . . . . . . . . . . . .
dec_stat_1/07 Declaration of Conformity for European Community (CE) Products . This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W .
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OM-222 166 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ihom _2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-222 166 Page 2 FIRE OR EXPLOSION hazard. D Do not overheat parts. D W atch for fire; keep extinguisher nearby . D Keep flammables away from work area. D Do not locate unit on, over , or near combustible surfaces. D Do not install unit near flammables.
OM-222 166 Page 3 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-222 166 Page 4 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION ihom _2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-222 166 Page 5 D À l’intérieur , ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz.
OM-222 166 Page 6 LE RA YONNEMENT HAUTE FRÉ- QUENCE (HF) risque de provoquer des interférences. D Le rayonnement haute fréquence (HF) peut provoquer des interférences avec les équipe- ments de r a d io - n a vi g a t i on e t de c o m mu ni c a t i on , l e s se rv i ce s de sécurité et les ordinateurs.
OM-222 166 Page 7 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from wiring can kill. 1.1 Wear dry insulating gloves. Do not wear wet or damaged gloves.
OM-222 166 Page 8 3-2. W arning Label Definitions (Continued) 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Overuse can cause overheating. Follow rated duty cycle. 4 Disconnect input plug or power before working on machine.
OM-222 166 Page 9 226 534-B 3-3. Rating Label For CE Products . For label location see Section 4-2. 3-4. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle W aste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility .
OM-222 166 Page 10 3-5. Symbols And Definitions . Some symbols are found only on CE products. A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Protection Ou.
OM-222 166 Page 1 1 4-2. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label (Non CE Models Only) Use rating label to determine input power needs.
OM-222 166 Page 12 4-4. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
OM-222 166 Page 13 4-5. Connecting 3-Phase Input Power For 460/575 V olt Models 803 994-C 3/8 in T ools Needed: ! Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. ! Disconnect and lockout/tagout in- put power before connecting input conductors from unit.
OM-222 166 Page 14 Ref. 804 430-A T ools Needed: 4-6. Connecting 3-Phase Input Power For 400/460 V olt Models 3/8 in ! Installation must meet all National and Local Codes − have only qualified per- sons make this installation. ! Disconnect and lockout/tagout input power before connecting input con- ductors from unit.
OM-222 166 Page 15 Ref. 803 993-C / Ref. 804 217-A 4-7. Power Source Output Connections 1 Output Connector 1 2 Output Connector 2 3 Protective Plug 4 Air-Cooled Extension Cable 5 Liquid-Cooled Extension Cable The power source is capable of single or dual output.
OM-222 166 Page 16 803 993-C 4-8. Remote 14 Receptacle RC14 Information and Connections 1 Plug 2 Threaded Collar 3 Keyway 4 Remote 14 Receptacle RC14 (See Section 4-9) T o connect to receptacle, align key- way , insert plug and tighten threaded collar .
OM-222 166 Page 17 803 993-C 4-10. T emperature Recorder Receptacle RC9 Information And Connections 1 Plug 2 Threaded Collar 3 T emperature Recorder Receptacle RC9 (See Section 4-1 1) T o connect to receptacle, insert plug and tighten threaded collar .
OM-222 166 Page 18 803 994-B / Ref. 801 826-C / Ref. 801 828-C 4-12. Secondary Insulation Protection Secondary insulation protection circuitry automatically shuts down the power source output if a potentially hazardous condition exists at the heating device connected to the power source (e.
OM-222 166 Page 19 803 993-C 4-13. 1 15 V olt AC Duplex Receptacle And Supplementary Protector 1 1 15 V AC 2.5 A Single-Phase AC Receptacle RC1 2 Supplementary Protector CB1 (2.5 A) Th e receptacle supplies nominal 1 15 volts ac auxiliary power for use with the optional digital recorder .
OM-222 166 Page 20 9. The following describes the thermocouple routing from work to power source. S T ype K thermocouple wire (two wire) is attached directly to the workpiece using a Thermocouple Attachment Unit (see next section for information on attaching thermocouples).
OM-222 166 Page 21 4-15. Attaching Welded Thermocouples . Do NOT weld thermocouples while connected to power source. 1. Attach thermocouples using a portable Thermocouple Attachment Unit (TAU). This unit spot welds thermocouple wire directly to the workpiece.
OM-222 166 Page 22 4-16. Using Contact Thermocouples Th e welded thermocouples discussed previously can be used for preheating or stress relieving. As an alternative, in preheating applications, a contact temperature sensor* can be used.
OM-222 166 Page 23 SECTION 5 − COMPONENTS AND CONTROLS 5-1. Controls . When a control panel button is pushed the yellow lamp lights to indicate ac- tivation. 1 Power Switch Use switch to turn power source On and Of f. 2 TC1 − 4 T emperature Display Provides temperature display of thermo- couples 1 through 4.
OM-222 166 Page 24 SECTION 6 − SETUP AND OPERA TION 6-1. Safety Equipment W ear the following during operation: 1 Dry, Insulating Gloves 2 Safety Glasses With Side Shields DO NOT wear rings or watches during operation.
OM-222 166 Page 25 Possible selections: Degree Units: ° F / ° C T olerance: ± 5 to 99 in ° F ( ± 3 to 55 in ° C) Backlight: Y es / No Input T ype: K TC Control Mode: T emp / Time / Manual Power Output: 1 to 35 System Lock: Y es / No Degree Units − press the Increase or Decrease buttons to select temperature units.
OM-222 166 Page 26 T o reset the system back to factory default settings, turn of f the power source, and wait until the display goes blank. T urn on the power source. When the display lights, press and hold the Increase and Decrease buttons. A message will display Press Program to reset factory defaults.
OM-222 166 Page 27 6-4-1-2. Bake-Out The bake-out process allows the operator to program a temperature and soak time as well as a cooling rate from bake-out if desired. When this process is selected, the following screen appears on the display: Mode..
OM-222 166 Page 28 Th 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, 1,2,3, or 1,2,3,4. TC1 MUST always be a control thermocouple.
OM-222 166 Page 29 Mode.......: Custom Program Segment....: 1 Type.......: End Control TC.: 1 Custom Program Screen The default position of the cursor is next to Segment. Press the Increase or Decrease button to increase or decrease the segment number , unless the segment type is End.
OM-222 166 Page 30 Mode.......: Custom Program Segment....: 1 Type.......: Ramp Temperature: 600 Ramp Rate: 600 _ /Hr Custom Program Screen Use the Cursor button to move the cursor to the T emperature or Ramp Rate position and use the Increase or Decrease button to set the desired value.
OM-222 166 Page 31 Soak Function When type is set to Soak, the following screen appears on the display: Mode.......: Custom Program Segment....: 1 Type.......:>Soak Soak Time..: 00:01:00 Custom Program Screen Us e the Cursor button to move the cursor to the Soak Time position and use the Increase or Decrease button to set the desired value.
OM-222 166 Page 32 T ypical 5-Segment Custom Program Mode.......: Custom Program Segment....: 1 Type.......:>Step Temperature: 600 Custom Program Screen T emperature increases to 600 degrees at full-programmed power . Mode.......: Custom Program Segment.
OM-222 166 Page 33 Mode....: Manual Power..: 0.0 KW Command.: 0.0 KW Current: 0 A Run Time: 00:03:00 Voltage: 0 V Frequency: 4.5 KHz Manual Program Screen The only programmable selections are Command power and Run T ime.
OM-222 166 Page 34 6-5-2. Manual Control Mode.....: Manual TC5: 77 Power....: 0.0 KW TC6: 77 Countdown: −− : −− : −− Status...: Stopped Run Status Screen During active operation, Power sho.
OM-222 166 Page 35 . The Cooler button is inactive when no cooler is detected and no liquid-cooled output cable is attached. 6-8. Real-Time Operation Each time the unit is first turned On it initiates a system check routine that includes verification of communication between circuit boards and checking for output isolation faults.
OM-222 166 Page 36 In addition, when running in Manual operating mode, the Hold button is not functional. If the system is running in Manual operating mode, pressing the Hold button will cause the fol.
OM-222 166 Page 37 6-9. System Operating Characteristics The power source delivers a high-frequency alternating current output that energizes the coil creating the magnetic field used to heat the workpiece.
OM-222 166 Page 38 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions.
OM-222 166 Page 39 SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 8-1. Symbol Usage OM-222166J - 2007 − 06, safety_ihtm 2007 − 04 DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-222 166 Page 40 MOVING P ARTS can cause injury . D Keep away from moving parts such as fans. D Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary . D Keep hands, hair , loose clothing, and tools away from moving parts.
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 .
OM-222 166 Page 42 9-2. Limit Conditions A limit condition indicates that the system has encountered an open thermocouple or is outside the range of its optimum operating conditions or parameters. Should a limit condition occur during operation, the yellow Limit LED will flash to indicate a problem.
OM-222 166 Page 43 Limit Condition Additional Information L1 1: Coolant Overtemp Limit Check coolant flow and level Clean coolant filters and heat exchanger Increase number of turns V erify appropriat.
OM-222 166 Page 44 Fault Condition Additional Information F67: Over Frequency Fault V erify heating cable properly wrapped V erify material being heated is magnetic F68: Cable Connection Fault Check f.
OM-222 166 Page 45 S OPEN − no cable or plug in place ClntFR − This is the coolant flow rate (in GPM) from the cooler on a liquid-cooled system. ClrSts − This is the status of the cooler .
OM-222 166 Page 46 9-7. Removing W rapper and Measuring Input Capacitor V oltage ! 900 V olts dc can be present on the capacitor bus and significant DC voltage can remain on capacitors after unit is Off. Always check the voltage on inverter assembly as shown to be sure the input capacitors have discharged before working on unit.
OM-222 166 Page 47 9-8. Blowing Out Inside Of Unit ! T urn Off welding power source and disconnect input power . ! Remove wrapper and be sure input capacitors are discharged. Blow out inside of unit. Blow out fan motors i n right side panel and front panel.
OM-222 166 Page 48 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram.
OM-222 166 Page 49 218 057-G.
OM-222 166 Page 50 SECTION 1 1 − P ARTS LIST . Hardware is common and not available unless listed. Figure 1 1-1. W rappers 804 218-D 1 3 5 6 7 8 11 9 10 11 See Figure 1 1-2 See Figure 1 1-3 4 2 12 13 14 15 Quantity Description Part No. Dia. Mkgs. Item No.
OM-222 166 Page 51 . Hardware is common and not available unless listed. Figure 1 1-2. Front Panel 804 219-A 1 2 3 11 8 12 4 5 13 6 7 9 10 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Front Panel 1 217 323 P ANEL, front 1 . . . . . .
OM-222 166 Page 52 . Hardware is common and not available unless listed. Figure 1 1-3. Rear Panel 804 220-A 1 3 8 11 6 4 2 9 10 12 13 5 14 7 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Rear Panel 1 217 324 P ANEL, rear 1 . . . . . .
OM-222 166 Page 53 . Hardware is common and not available unless listed. Figure 1 1-4. Base w/Components 804 221-D 1 14 4 2 13 7 6 14 6 5 9 10 8 3 12 3 15 16 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-4 . Base w/Components 1 217 328 FRAME, lifting 1 .
OM-222 166 Page 54 . Hardware is common and not available unless listed. Figure 1 1-5. T op Windtunnel 804 222-A 1 3 5 2 8 7 11 10 9 13 12 6 14 15 4 See Figure 1 1-6 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-5 . T op Windtunnel 1 218 424 WINDTUNNEL, top 1 .
OM-222 166 Page 55 . Hardware is common and not available unless listed. Figure 11-6. Capacitor Assembly 804 223-A 1 2 3 4 Quantity Description Part No. Dia. Mkgs. Item No. Figure 11-6 . Capacitor Assembly 1 C3-C6 218 685 CAP ACITOR, popyp met film 1.
OM-222 166 Page 56 . Hardware is common and not available unless listed. 804 224-E 1 6 7 5 4 16 12 3 10 9 11 8 18 13 14 15 17 2 19 20 Figure 1 1-7. Right Windtunnel Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-7. Right Windtunnel 1 216 630 WINDTUNNEL, RH 1 .
OM-222 166 Page 57 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-7. Right Windtunnel (Continued) 17 229 728 STRAP , connecting 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 166 Page 58 . Hardware is common and not available unless listed. 804 431-E 2 1 6 7 5 4 14 3 10 9 11 8 17 16 22 15 13 19 12 20 15 21 Figure 1 1-8. Right Windtunnel (400 V Model Only) Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-8 .
OM-222 166 Page 59 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-8 . Right Windtunnel (400 V Model Only) (Continued) 19 208 591 SCREW , M 5 − .8X 12 soc hd − torx stl pld sems 14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 166 Page 60 . Hardware is common and not available unless listed. Figure 1 1-9. Left Windtunnel 804 225-A 2 12 6 13 7 4 11 15 9 3 5 14 8 1 10 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-9. Left Windtunnel 1 216 631 WINDTUNNEL, LH 1 .
OM-222 166 Page 61 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-9 . Left Windtunnel (Continued) PLG16, . . . . . . . 121,122 131 054 HOUSING RCPT+SKTS,(SER VICE KIT) 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG19, .
OM-222 166 Page 62 . Hardware is common and not available unless listed. Figure 1 1-10. Hermaphroditic Blank Plug Assy 804 300-A 1 2 3 4 5 3 4 6 7 8 1 9 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-10. Hermaphroditic Blank Plug Assy 1 221 440 O-RING, .
OM-222 166 Page 63 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .
OM-222 166 Page 64 Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Compan y 1635 W est S pencer Street Applet on, WI 5 4914 USA International He adquarte rs.
An important point after buying a device Miller Electric ProHeat 35 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric ProHeat 35 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric ProHeat 35 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric ProHeat 35 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric ProHeat 35 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric ProHeat 35, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric ProHeat 35.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric ProHeat 35. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric ProHeat 35 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
