Instruction/ maintenance manual of the product TS Miller Electric
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IH/TS Processes Description OM-203 185F 2005 − 09 Induction Heating Single Induction Heating Power Source T emperature Control/Recorder Visit our website at www.
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T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS 6-3-5. Recovering From An Interruption 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-6. V iewing Data In Review Software 32 . . . . . . . . . . . . . . . . . . . .
OM-203 185 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage safety_ihom 5/05 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-203 185 Page 2 FIRE OR EXPLOSION hazard. D Do not overheat parts and adhesive. 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-203 185 Page 3 1-6. EMF Information Considerations About Induction Heating And The Effects Of Low Fre- quency Electric And Magnetic Fields Th e following is a quotation from the General Conclusions Section of the U.
OM-203 185 Page 4 SECTION 2 − MESURES DE SECURITE POUR LE CHAUFF AGE P AR INDUCTION ihom_fre 8/03 PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRA VES, VOIRE MORTELLES. TENIR LES ENF ANTS A DIST ANCE. LES PORTEURS D’UN STIMULA TEUR CARDIAQUE DOIVENT PREALABLEMENT CONSUL TER LEUR MEDECIN.
OM-203 185 Page 5 DES FUMEES ET DES GAZ peuvent être dangereux pour votre santé. Le chauf fage à induction génère des fumées et des gaz. Leur inhalation peut être dangereuse pour votre santé. 1. Eloigner la tête des fumées. Ne pas respirer les fumées.
OM-203 185 Page 6 2-2. Informations concernant les champs électro-magnétiques (Information EMF) Considérations relatives au chauffage à induction et aux ef fets des champs électriques et magnétiques basse fréquence. Le texte suivant est extrait des conclusions générales Département du Congrès U.
OM-203 185 Page 7 SECTION 3 − INTRODUCTION The Induction Heating T emperature 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 dif ferent configurations; as a controller only or as a controller with a digital recorder .
OM-203 185 Page 8 SECTION 4 − INST ALLA TION 4-1. Specifications Specification Description Overall Dimensions Height: 10 in (254 mm); Width: 14-1/2 in (368 mm); Depth: 16 in (406 mm) W eight Net: IH/TS (no recorder) 13.1 lb (5.9 kg); IH/TS (digital recorder) 21.
OM-203 185 Page 9 4-3. Connecting T o Power Source T ur n Off power source. 1. IH/TS 2. Interconnecting 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.
OM-203 185 Page 10 4-5. Connecting 25kW System Cords And Cables Connect the power output cable and coolant lines as shown. Connect 1 10-volt power cable as shown. Plug the 1 10-volt cooler power cord into th e duplex at the rear of the power source cart.
OM-203 185 Page 1 1 4-6. Connecting 5kW System Cords And Cables Connect the power output cable and coolant lines as shown. Connect 1 10-volt power cable as shown. Plug the 1 10-volt cooler power cord into th e duplex at the rear of the power source cart.
OM-203 185 Page 12 4-7. Connecting External Device The IH/TS 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. T o connect thermocouples to the control, proceed as follows: T urn Off power source.
OM-203 185 Page 13 SECTION 5 − COMPONENTS AND CONTROLS 5-1. IH/TS Front Panel Y Keep all panels, doors, and covers closed and secure during programming. 1. T emperature Controller 2. Parameter Display Screen 3. Heat On Pilot Light 4. Fault/ Limit Light 5.
OM-203 185 Page 14 5-2. IH/TS Rear Panel Y Keep all panels, doors, and covers closed and secure during programming. 1. Thermocouple Connectors 2. On/Of f Power Switch 3. 1 15 V AC Power Cord 4. 14-Pin Receptacle 5. Coolant Flow Switch “IN” Fitting 6.
OM-203 185 Page 15 5-3. Controller Y Keep all panels, doors, and covers closed and secure during programming. 1. Digital Display 2. Page Forward Button 3. Scroll Button 4. Down Button 5. Up Button 6. Actual T emperature 7. Setpoint T emperature 8. Auto/Man Button (Disabled) 9.
OM-203 185 Page 16 SECTION 6 − SETUP AND OPERA TION 6-1. Safety Equipment W ear the following during operation: 1. Dr y , Insulating Gloves 2. Safety Glasses With Side Shields DO NOT wear rings or watches during operation. sb3.1* 1/94 12 6-2. IH/TS Setup 6-2-1.
OM-203 185 Page 17 6-2-2. Time Date Setup − Digital 6-2-2-1. Digital Recorder Controls Y Keep all panels, doors, and covers closed and secure during programming. 1. Page Up 2. Page Down 3. Left 4. Right 5. Option 6. Menu Additional keys that appear as needed for specific applications are as follows: 7.
OM-203 185 Page 18 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.
OM-203 185 Page 19 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. Se t up T emperature Profile − per code requirements (see Section 6-3-2 Programming The 2408 Controller).
OM-203 185 Page 20 6-3-1. 2408 Controller The 2408 controller in the IH/TS provides a 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.
OM-203 185 Page 21 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.
OM-203 185 Page 22 Step to 3 00 ° F as fast as possible Dwell @ 300 ° F for 8 hours Free fall to ambient SEG.n 1 tYPE StEP tGt 300 (step) (deg) SEG.n 2 tYPE dwEl dur 8.
OM-203 185 Page 23 Step to 6 00 ° F as fast as possible* Ramp to 1350 ° F @ 600 ° /hr SEG.n 1 tYPE StEP tGt 600 (step) (deg) SEG.n 2 tYPE rmP.r tGt 1350 (ramp rate) SEG.n 3 tYPE dwEl dur 0.5 (soak) (in hrs) 0 200 400 600 800 1000 1200 1400 0 30 60 90 120 150 180 Time (minutes) Degrees F Example Stress Relief Profile SEG.
OM-203 185 Page 24 Step to 600 ° F as fast as possible Ramp to 800 ° F @ 400 ° /hr SEG.n 1 tYPE StEP tGt 600 (step) (deg) SEG.n 2 tYPE rmP.r tGt 800 (ramp rate) SEG.n 4 tYPE dwEl dur 1.0 (soak) (in hrs) 0 200 400 600 800 1000 1200 1400 0.0 1.0 2.0 3.
OM-203 185 Page 25 A A TGT C rAtE ( ° /hr) B TGT D dur (hrs) F rAtE ( ° /hr) E TGT SEG.n 1 tYPE StEP (step) TGT (target) (deg) SEG.n 2 tYPE rmP.r (ramp rate) B TGT (target) (deg) C rAtE (deg/hr) D SEG.n 3 tYPE dwEl (soak) dur (duration in hrs) SEG.n 4 tYPE rmP.
OM-203 185 Page 26 6-3-3. Batch Recording Using 5100 Digital Recorder The batch file generated by the recorder will consist of: GroupDescriptor ~ BatchName ~ T imeDateStamp.uhh The default Group Descriptor is set to “Group”. This setting may be changed to something that relates to the application (i.
OM-203 185 Page 27 6-3-3-3. Stop Recording 1. T ouch the block with the batch name. 2. T ouch “Stop”. 3. T ouch “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.
OM-203 185 Page 28 6. Close the “Network and Dial-up Connection” window . 7. Close the “Control Panel”. Network Connection (Windows ) 95, 98, ME) 1. Click on “Start”, “Settings”, “Control Panel”. 2. Right click on “Network”. 3.
OM-203 185 Page 29 3. Click on “Instrument”, “File Services”. 4. Click on “Generic”. 5. Enter user name: “user” (leave password field blank). 6. Click on “OK”. 7. Right click on desired files and transfer them following the procedures in Sections 6-3-6 and 6-3-7.
OM-203 185 Page 30 6-3-4. Running A Program T o Preheat Or Stress Relief T o start the Heat T reat 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”.
OM-203 185 Page 31 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.
OM-203 185 Page 32 6-3-6. V iewing 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.
OM-203 185 Page 33 There are 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 FilesEurothermReviewReview.erv file contains a copy of the original data and any annotations added in the Review software.
OM-203 185 Page 34 scrn38 Select “Files” . scrn3 Select the “history” folder on the floppy drive or browse to the folder on the PC that contains the .
OM-203 185 Page 35 Single File With Batch Name scrn4 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” .
OM-203 185 Page 36 Single File With No Batch Name scrn6 Data is continuously stored in the recorder . 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 ∼ T ime/Date_stamp.
OM-203 185 Page 37 Multiple Files With Batch Names scrn8 Data is continuously stored in the recorder . The file name consists of: Group_Descriptor ∼ Batch_Name ∼ Time/ Date_stamp.uhh Select the desired files. Select “Open” . Multiple Files With No Batch Names scrn9 If a batch was not started, the temperature data is still recorded.
OM-203 185 Page 38 scrn1 1 New instrument is displayed. Select “ OK ” to add the Instrument tag. scrn12 Select “ File ”. Select “ New Chart ”.
OM-203 185 Page 39 scrn14 Select Instrument, this is the Instrument tag [Job# (Batch Name)] that was entered previously . scrn15 Select the appropriate Log Group. Select Point ID to add a specific point, then select “ OK ” or Select “ Add All ”.
OM-203 185 Page 40 scrn16 Change “Grid Major divisions:” to 30 resulting in 50 ° increments from 0-1500 ° F . Select “ OK ” to view chart scrn17 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.
OM-203 185 Page 41 scrn18 Drag the slider on the left down to zoom the view out. Click the maximize box to enlarge to full screen. Click on the profile, the dashed line moves to the cursor location. The values at the cursor location appear on the right side of the screen.
OM-203 185 Page 42 scrn20 T o remove a TC, click on the TC# (Point ID), then click “ Delete Point ”. T o edit a TC trace properties, select a TC# (Point ID), then click “ Point Properties... ”. Select “ OK ” to return to the chart. scrn21 Span − dictates the range of tem- perature to plot for the trace.
OM-203 185 Page 43 scrn22 Comments can be added to the chart by selecting “ Annotate ” from the Chart Menu . scrn23 Add comments in the Annotation field. Add time manually . Select “OK ”. (10:56:00 A M) scrn24 A warning will appear on the display stating that once added, the com- ment cannot be deleted or changed.
OM-203 185 Page 44 scrn25 Save chart to floppy disk by select- ing “File”, then select “Save chart As...” scrn26 / scrn27 Select a path to “ Save in ”. Enter “ File name ” to save as. . File name should be the same as the Instrument name and Job# (Batch Name) for consistency .
OM-203 185 Page 45 scrn28 The file name becomes part of the chart scrn29 Select “ File ”. Select “ Print ” to print entire profile on one page.
OM-203 185 Page 46 scrn30 Select “ Batch ”. Click in check box to select “ Print entire batch ”. Select “ Batch Name “ from pull down menu.
OM-203 185 Page 47 6-3-8. T ypical Profile Chart Printout.
OM-203 185 Page 48 SECTION 7 − CONFIGURING CONTROLLER AND RECORDER 7-1. Changing Controller Operating Window , Ramp, Dwell, Or T emperature Units Use the following instructions if changes are required to Operating Window , Ramp, Dwell, or T emperature units.
OM-203 185 Page 49 7-2. Changing 5100V Recorder From Degrees F to Degrees C And Change TC Descriptor scrn32 Log in as “ Engineer ” (see Section 6-2-2-2 ). Press “ Menu ” (bottom right of display). Select “ Config “. Select “ Channels ” from pull down menu.
OM-203 185 Page 50 7-3. Restoring Recorder Configuration From A Floppy Disk (For 5100 Digital Recorder) Login as Engineer . T ouch top left corner (Logged Out) or (User). T ouch Blue text (pull down menu) next to User . T ouch Engineer . T ouch Password field.
OM-203 185 Page 51 7-3-3. Time Setup 1. T ouch System. 2. T ouch Clock. 3. Adjust time, if necessary . 4. T ouch Apply . 7-3-4. Login As User 1. T ouch top left corner (Engineer). 2. T ouch pull down next to User . 3. T ouch User from pull down list. 7-3-5.
OM-203 185 Page 52 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance T urn Off all power before maintaining. 3 Months OR Blow Out Or V acuum Inside Replace Unreadable Labels 6 Months Replace Cracked Parts 8-2. T roubleshooting T rouble Remedy IH/TS does not power up.
OM-203 185 Page 53 T rouble Remedy If display flashes no.io 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.
OM-203 185 Page 54 T rouble Remedy 2408 T emperature Controller reads greater than 5 ° F different than Channel 1 on 5100V Recorder . See Section 8-3I. 2408 T emperature Controller readings fluctuate rather than remain stable. Check and secure connections to the workpiece.
OM-203 185 Page 55 8-3. Diagnostic Procedures For IH/TS A. Parameter Display Does Not Operate, But 2408 T emperature Controller And 5100V Recorder Displays Do Operate. T urn 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.
OM-203 185 Page 56 Check for 1 15 volts ac at plug on rear of recorder and reseat plug. If 1 15 volts ac is not present, check wiring between plug PLG4, receptacle RC4, and power switch. If 1 15 volts ac is present at plug on rear of recorder , check that green LED is illuminated by viewing through louvers on side of recorder .
OM-203 185 Page 57 Check Flow/Limit light for illumination. If light does not illuminate, replace circuit board PC1. If light does illuminate, proceed as follows: Check switch leads for continuity when switch is activated. Check switch leads for open circuit when switch is deactivated.
OM-203 185 Page 58 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 . I. 2408 T emperature Controller Reads Greater Than 5 5 F Different Than Channel 1 On 5100V Recorder Remove IH/TS wrapper .
OM-203 185 Page 59 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. T o access the Goto screen, proceed as follows: Press Page to AccS LiSt codE 0 Y codE 1 W ait 2 sec.
OM-203 185 Page 60 8-5-2. 2408 Controller Edit Parameters Goto Edit Home Run P ro gr a m m e r Alarm Autotune PID Setpoint I nput Output Information Access List List List List List List List List List.
OM-203 185 Page 61 8-5-3. 2408 Controller Full Parameters (Prior T o V ersion V4.09) Goto FuLL Ho me Run Programmer Alarm Autotune P I D Setpoint Input Output Information Access List List List List Li.
OM-203 185 Page 62 8-5-4. 2408 Controller Configure Parameters (Prior T o V ersion V4.09) Goto conF Process Logical Logical Alarm Instrument V alue Input Setpoint Alarms Programmer Inputs A Inputs B r.
OM-203 185 Page 63 8-5-5. 2408 Controller Full Parameters (Effective w/V ersion V4.09) Goto FuLL Ho me Run Programmer Alarm Autotune PI D Setpoint Input Output Information Access List List List List L.
OM-203 185 Page 64 8-5-6. 2408 Controller Configure Parameters (Effective w/V ersion V4.09) Goto conF Process Logical Logical Alarm Instrument V alue Input Setpoint Alarms Programmer Inputs A Inputs B.
OM-203 185 Page 65 8-6. Calibration Certification Procedure The following items are required for verifying calibration: 1. Fluke-714 Thermocouple Calibrator this can be obtained from: http://www .fluke.com/products/home.asp?SID=13&AGID=9&PID=1707 specify primary standard certification when ordering.
OM-203 185 Page 66 SECTION 9 − ELECTRICAL DIAGRAMS 215 588-A Figure 9-1. Circuit Diagram For IH/TS.
OM-203 185 Page 67 SECTION 10 − P ARTS LIST Ref. 803 005-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 25 26 27 28 29 30 32 34 35 36 37 38 39 40 41 42 43 23 24 17 33 31 Figure 10-1. Complete Assembly Description Part No. Dia. Mkgs. Figure 10-1.
OM-203 185 Page 68 Description Part No. Dia. Mkgs. Figure 10-1. Complete Assembly (Continued) Quantity 22 198 893 RECEPT ACLE, thermocouple 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 209 948 BRACKET , mtg receptacle RJ45 2 .
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PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US.
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