Miller Electric IH Owner's Manual
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Miller Electric IH Owner's Manual

Miller Electric IH Owner's Manual

Single induction heating power source temperature control/recorder
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IH/TS
OM-203 185F
2005−09
Processes
Induction Heating
Description
Single Induction Heating Power Source
Temperature Control/Recorder
File: Induction Heating

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  • Page 1 Visit our website at www.MillerWelds.com OM-203 185F 2005−09 Processes Induction Heating Description Single Induction Heating Power Source Temperature Control/Recorder IH/TS File: Induction Heating...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.

  • Page 3: Table Of Contents

    6-3-3-5. Saving Data To A PC (Alternative To Floppy Disk) 6-3-3-5-1. Review Software − First Time Setup 6-3-3-5-2. Creating A Shortcut − First Time Setup 6-3-3-5-3. Changing IP Address To Connect The IH/TS 6-3-3-5-4. Downloading Files From Recorder 6-3-3-5-5. Troubleshooting Connection Problems 6-3-3-5-6.
  • Page 4 ..............8-3. Diagnostic Procedures For IH/TS 8-4.

  • Page 5: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 6: Additional Symbols For Installation, Operation, And Maintenance

    FIRE OR EXPLOSION hazard. D Do not overheat parts and adhesive. D Watch for fire; keep extinguisher nearby. D Keep flammables away from work area. Do not locate unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not operate unit in explosive atmosphere.

  • Page 7: Emf Information

    1-6. EMF Information Considerations About Induction Heating And The Effects Of Low Fre- quency Electric And Magnetic 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 − Background Paper, OTA- BP-E-53 (Washington, DC: U.S.

  • Page 8: Section 2 − Mesures De Securite Pour Le Chauffage Par Induction

    SECTION 2 − MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION AVERTISSEMENT PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS D’UN STIMULATEUR CARDIAQUE DOIVENT PREALABLEMENT CONSULTER LEUR MEDECIN. Pendant les opérations de chauffage, comme dans la plupart des activités, l’opérateur s’expose à...

  • Page 9: Dangers Supplémentaires De Mise En Route, De Fonctionnement Et D'entretien

    DES FUMEES ET DES GAZ peuvent être dangereux pour votre santé. Le chauffage 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. 2.

  • Page 10: Informations Concernant Les Champs Électro-Magnétiques (Information Emf)

    2-2. Informations concernant les champs électro-magnétiques (Information EMF) Considérations relatives au chauffage à induction et aux effets des champs électriques et magnétiques basse fréquence. Le texte suivant est extrait des conclusions générales Département du Congrès U.S., Office of Technology Assessment, Effets biologiques des champs magnétiques et électriques basse fréquence −...

  • Page 11: Section 3 − Introduction

    The controller in the IH/TS comes pre-programmed from the factory with a typical stress relieving temperature profile that can be easily changed to match specific customer stress relief requirements. Also, the controller can be programmed to operate in a pre-heat mode.

  • Page 12: Section 4 − Installation

    Height: 10 in (254 mm); Width: 14-1/2 in (368 mm); Depth: 16 in (406 mm) Weight Net: IH/TS (no recorder) 13.1 lb (5.9 kg); IH/TS (digital recorder) 21.1 lb (9.6 kg) Type Of Input Power 24 Volts DC, 115 Volts AC...

  • Page 13: Connecting To Power Source

    Actual frequency input signal. Average power input signal. Voltage input signal RMS. Current input signal RMS. Turn 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.

  • Page 14: Connecting 25Kw System Cords And Cables

    Hose From Cooler IH/TS To Cooler plug. The IH/TS Control is plugged in the left side duplex. Do not use these duplex connections for operating auxiliary tools, such as grinders, drills, lights, etc. Connect output power cables to the output connectors.

  • Page 15: Connecting 5Kw System Cords And Cables

    Rear Hose From Cooler To Output Extension Cable The IH/TS Control is plugged in the left side duplex. Do not use these duplex connections for operating auxiliary tools, such as grinders, drills, lights, etc. Connect the “coolant out” line from the cooler directly to the output ex- tension cable.

  • Page 16: Connecting External Device

    4-7. Connecting External Device Tools Needed: 11/16 in OM-203 185 Page 12 The IH/TS must have (as a minimum) thermocouple connected to receptacle TC1. If multiple thermocouples desired, either individual thermocouple plugs thermocouple extension cable. To connect thermocouples to the control, proceed as follows: Turn Off power source.

  • Page 17: Section 5 − Components And Controls

    SECTION 5 − COMPONENTS AND CONTROLS 5-1. IH/TS Front Panel Y Keep all panels, doors, and covers closed and secure during programming. 1. Temperature Controller 2. Parameter Display Screen 3. Heat On Pilot Light 4. Fault/ Limit Light 5. Run Button 6.

  • Page 18: Ih/Ts Rear Panel

    5-2. IH/TS Rear Panel OM-203 185 Page 14 Y Keep all panels, doors, and covers closed and secure during programming. 1. Thermocouple Connectors 2. On/Off Power Switch 3. 115 VAC Power Cord 4. 14-Pin Receptacle 5. Coolant Flow Switch “IN”...

  • Page 19: Controller

    5-3. Controller 200.0 200.0 AUTO HOLD 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 Temperature 7. Setpoint Temperature 8.

  • Page 20: Section 6 − Setup And Operation

    Select Power Source Energize the power source, cooler, and IH/TS. A power source selection will appear in the top right corner of the IH/TS front panel Parameter Display. Press the recessed Power Source Select button on the IH/TS rear panel to toggle through and select the appropriate power source maximum output.

  • Page 21: Time Date Setup − Digital

    6-2-2. Time Date Setup − Digital 6-2-2-1. Digital Recorder Controls 6-2-2-2. Login As Engineer 1. Touch top left corner (Logged Out) or (User). 2. Touch Blue text (pull down menu) next to User. 3. Touch Engineer. 4. Touch Password field. 5.

  • Page 22: Time And Date Setup

    NOTE 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. 8. Touch Apply. 6-2-2-5. Time And Date Setup 1.

  • Page 23: Operation

    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. Set up Temperature Profile − per code requirements (see Section 6-3-2 Programming The 2408 Controller).

  • Page 24: 2408 Controller

    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. The 2408 controller has several screens (main and sub-menu) that are used to monitor status and program the control.

  • Page 25: Programming The 2408 Controller

    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. Use worksheet in Figure 6-4 to help prepare either a pre- or post-heat temperature profile.
  • Page 26 Step to 300 F Dwell @ 300 F as fast as for 8 hours possible SEG.n SEG.n tYPE tYPE StEP dwEl (step) (soak) (deg) (in hrs) Figure 6-1. Setting Pre-heat Profile Using Example Parameters OM-203 185 Page 22 Free fall to ambient SEG.n tYPE...
  • Page 27 Step to 600 F Ramp to 1350 F as fast as @ 600 /hr possible* SEG.n SEG.n tYPE tYPE StEP rmP.r (step) (ramp rate) 1350 (deg) (deg) rAtE (deg/ hr) 1400 1200 1000 *On small diameter pipe, it may be necessary to reduce the output of the power source to achieve a “reasonable rate”...
  • Page 28 Step to Ramp to 800 F Ramp to 1250 F 600 F as fast as @ 400 /hr possible SEG.n SEG.n tYPE tYPE StEP rmP.r (step) (ramp rate) (deg) (deg) rAtE (deg/ hr) 1400 1200 1000 *On small diameter pipe, it may be necessary to reduce the output of the power source to achieve a “reasonable rate”...
  • Page 29 rAtE ( /hr) SEG.n SEG.n tYPE tYPE StEP rmP.r (step) (ramp rate) (target) (target) (deg) (deg) rAtE (deg/hr) 1. Identify Target temperatures, Ramp Rates, and Dwell Time. 2. Insert Values into profile. Figure 6-4. Profile Set-Up Worksheet (hrs) SEG.n SEG.n tYPE dwEl rmP.r...

  • Page 30: Batch Recording Using 5100 Digital Recorder

    6-3-3. Batch Recording Using 5100 Digital Recorder The batch file generated by the recorder will consist of: GroupDescriptor~BatchName~TimeDateStamp.uhh The default Group Descriptor is set to “Group”. This setting may be changed to something that relates to the application (i.e. Company, Contract, or Project name). To change the Group Descriptor, proceed as follows: 1.

  • Page 31: Stop Recording

    6-3-3-3. Stop Recording 1. Touch the block with the batch name. 2. Touch “Stop”. 3. Touch “Close” − screen returns to the home screen and displays “No Batch In Progress”. NOTE If a batch file was not started, the temperature data is still recorded. The Job# (Batch Name), User, Comments, and Recorder ID are not recorded.

  • Page 32: Changing Ip Address To Connect The Ih/Ts

    10. Click on “Yes” to restart the computer and have changes take effect. 6-3-3-5-4. Downloading Files From Recorder 1. Connect a crossover cable between the IH/TS recorder and the PC (a crossover cable is a special network cable with pins 2 and 3 reversed on one end).

  • Page 33: Troubleshooting Connection Problems

    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. 6-3-3-5-5.

  • Page 34: Running A Program To Preheat Or Stress Relief

    6-3-4. Running A Program To Preheat Or Stress Relief To start the Heat Treat 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”. The controller flashes “Hold”...

  • Page 35: Recovering From An Interruption

    1) If the current temperature is more than 105 F above the target temperature in segment 1, the IH/TS will not require output from the power source. The blue Heat On light will be on and power source will not provide output. (Providing the Panel/Remote switch on the power source is in the remote position.)

  • Page 36: Viewing Data In Review Software

    6-3-6. Viewing 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.exe”.

  • Page 37: Running Review Software

    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 Files\Eurotherm\Review\Review.erv file contains a copy of the original data and any annotations added in the Review software.
  • Page 38 Select “Files”. scrn38 Select the “history” folder on the floppy drive or browse to the folder on the PC that contains the .uhh files. scrn3 OM-203 185 Page 34...
  • Page 39 Single File With Batch Name 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”. scrn4 Enter the Job# (Batch Name) in the field next to “Select or Enter Instrument tag:” This is the “File name”...
  • Page 40 Single File With No Batch Name OM-203 185 Page 36 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. file name would...
  • Page 41 Multiple Files With Batch Names Multiple Files With No Batch Names 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”. scrn8 If a batch was not started, the temperature data is still recorded.
  • Page 42 OM-203 185 Page 38 New instrument is displayed. Select “OK” to add the Instrument tag. scrn11 Select “File”. Select “New Chart”. scrn12 Select “Add Point”. scrn13...
  • Page 43 Select Instrument, this is the Instrument tag [Job# (Batch Name)] that was entered previously. scrn14 Select the appropriate Log Group. Select Point ID to add a specific point, then select “OK” Select “Add All”. scrn15 OM-203 185 Page 39...
  • Page 44 OM-203 185 Page 40 Change “Grid Major divisions:” to 30 resulting in 50 increments from 0-1500 F. Select “OK” to view chart scrn16 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.
  • Page 45 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.
  • Page 46 OM-203 185 Page 42 To remove a TC, click on the TC# (Point ID), then click “Delete Point”. To edit a TC trace properties, select a TC# (Point ID), then click “Point Properties...”. Select “OK” to return to the chart. scrn20 Span −...
  • Page 47 (10:56:00 AM) Comments can be added to the chart by selecting “Annotate” from the Chart Menu. scrn22 Add comments in the Annotation field. Add time manually. Select “OK”. scrn23 A warning will appear on the display stating that once added, the com- ment cannot deleted...
  • Page 48 OM-203 185 Page 44 Save chart to floppy disk by select- ing “File”, then select “Save chart As...” scrn25 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.
  • Page 49 The file name becomes part of the chart scrn28 Select “File”. Select “Print” to print entire profile on one page. scrn29 OM-203 185 Page 45...
  • Page 50 Select “Batch”. Click in check box to select “Print entire batch”. Select “Batch Name“ from pull down menu. Select “Print”. scrn30 OM-203 185 Page 46...

  • Page 51: Typical Profile Chart Printout

    6-3-8. Typical Profile Chart Printout OM-203 185 Page 47...

  • Page 52: Section 7 − Configuring Controller And Recorder

    SECTION 7 − CONFIGURING CONTROLLER AND RECORDER 7-1. Changing Controller Operating Window, Ramp, Dwell, Or Temperature Units NOTE Use the following instructions if changes are required to Operating Window, Ramp, Dwell, or Temperature units. AccS Press Page LiSt codE codE Wait 2 sec.

  • Page 53: Changing 5100V Recorder From Degrees F To Degrees C And Change Tc Descriptor

    7-2. Changing 5100V Recorder From Degrees F to Degrees C And Change TC Descriptor Log in as “Engineer” (see Section 6-2-2-2). Press “Menu” (bottom right of display). Select “Config“. Select “Channels” from pull down menu. scrn32 For each Channel Number (1-6): 1.

  • Page 54: Restoring Recorder Configuration From A Floppy Disk

    7-3. Restoring Recorder Configuration From A Floppy Disk (For 5100 Digital Recorder) Login as Engineer. Touch top left corner (Logged Out) or (User). Touch Blue text (pull down menu) next to User. Touch Engineer. Touch Password field. Touch Numeric. Touch 1, then 0, then Ok. 7-3-1.

  • Page 55: Time Setup

    7-3-3. Time Setup 1. Touch System. 2. Touch Clock. 3. Adjust time, if necessary. 4. Touch Apply. 7-3-4. Login As User 1. Touch top left corner (Engineer). 2. Touch pull down next to User. 3. Touch User from pull down list. 7-3-5.

  • Page 56: Section 8 − Maintenance & Troubleshooting

    Trouble IH/TS does not power up. Be sure that power switch on rear of IH/TS is in the On position. Check 115 volts ac at receptacle where IH/TS is plugged in. Be sure that IH/TS is not plugged into a switched receptacle.
  • Page 57 Output does not start when Run See Section 8-3F. button is pressed. Pressing Power Source Select See Section 8-3G. button on rear of IH/TS does not change selection. 5100V Recorder displays Channel See Section 8-3H. Error. Remedy For 25 kW system, ensure receptacle switch is on.
  • Page 58 Trouble 2408 Temperature Controller reads See Section 8-3I. greater than 5 F different than Channel 1 on 5100V Recorder. 2408 Temperature Controller Check and secure connections to the workpiece. readings fluctuate rather than remain stable. 5100V Recorder screen blinks Screen calibration needs adjusting. Turn off IHTS power switch. Turn on IHTS power switch while touching when touched, but does not screen, and continue to touch screen (about 45 seconds) until configuration display appears on the screen.

  • Page 59: Diagnostic Procedures For Ih/Ts

    If +24 volts dc is not present, consult power source Owner’s Manual for troubleshooting. Connect 14-pin control cable to power source. Check for +24 volts dc between pins A and D at IH/TS end of cable. If +24 volts dc is not present, replace 14-pin control cable.
  • Page 60 If circuit is not open, consult power source Owner’s Manual for troubleshooting. Reconnect IH/TS 115 volts ac power cord. If light illuminates, disconnect Coolant In (red) fitting from IH/TS. Spray silicone lubricant into fitting. Insert a long narrow screwdriver into fitting and actuate flow switch plunger several times.
  • Page 61 If 24 volts dc is present, replace LED. If 24 volts dc is not present, another source rather than the IH/TS is energizing the power source. Check for a short circuit between pins A and B in the 14-pin control cable.

  • Page 62: Resetting All Ram Variables In The Event Of Display Errors

    RAM memory reset operation. “MEMORY RESET” Display “MEMORY RESET” will appear on the display after completion of RAM memory reset. The IH/TS will restart with factory set default parameters in RAM memory.

  • Page 63: Factory Set Parameters

    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. To access the Goto screen, proceed as follows: AccS Press Page LiSt...

  • Page 64: 2408 Controller Edit Parameters

    8-5-2. 2408 Controller Edit Parameters OM-203 185 Page 60...

  • Page 65: 2408 Controller Full Parameters (Prior To Version V4.09)

    8-5-3. 2408 Controller Full Parameters (Prior To Version V4.09) OM-203 185 Page 61...

  • Page 66: 2408 Controller Configure Parameters (Prior To Version V4.09)

    8-5-4. 2408 Controller Configure Parameters (Prior To Version V4.09) OM-203 185 Page 62...

  • Page 67: 2408 Controller Full Parameters (Effective W/Version V4.09)

    8-5-5. 2408 Controller Full Parameters (Effective w/Version V4.09) OM-203 185 Page 63...

  • Page 68: 2408 Controller Configure Parameters (Effective W/Version V4.09)

    8-5-6. 2408 Controller Configure Parameters (Effective w/Version V4.09) OM-203 185 Page 64...

  • Page 69: Calibration Certification Procedure

    Repeat at 882.0 degrees F and at 1382.0 degrees F Save a copy of the Certificate using the IH/TS serial no. and date as the file name, i.e. “LB056241 062501” for June 25, 2001. Print a copy of the certificate to send with the IH/TS.

  • Page 70: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS 215 588-A Figure 9-1. Circuit Diagram For IH/TS OM-203 185 Page 66...

  • Page 71: Section 10 − Parts List

    SECTION 10 − PARTS LIST Dia. Part Mkgs. Figure 10-1. Complete Assembly ... . . 203 262 NAMEPLATE, w/o recorder ... . . 204 366 NAMEPLATE, w/recorder .
  • Page 72 152 492 RCPT W/PINS ... . 204 227 BRACKET, mtg IH/TS ... . 204 040 MOUNT, nprn 100mm recorder 55 durometer .
  • Page 73 Notes...
  • Page 74 Notes...
  • Page 75 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 76: Owner's Record

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2005 Miller Electric Mfg. Co. 1/05 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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