Miller 301182 Owner's Manual
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Miller 301182 Owner's Manual

Miller 301182 Owner's Manual

Induction heating accessory. proheat rolling inductor w/optional ir and travel detect
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ProHeat Rolling Inductor
w/Optional IR And Travel Detect
)
OM-261823F
2016−11
Processes
Induction Heating
Description
Induction Heating Accessory
File: Induction Heating

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  • Page 1 OM-261823F 2016−11 Processes Induction Heating Description Induction Heating Accessory ProHeat Rolling Inductor w/Optional IR And Travel Detect File: Induction Heating For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − MAINTENANCE AND TROUBLESHOOTING ........7-1.

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ihom _2015-09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    FIRE OR EXPLOSION hazard. INDUCTION HEATING can burn. D Do not overheat parts. D Do not touch hot parts bare-handed. D Watch for fire; keep extinguisher nearby. D Allow cooling period before handling parts or equipment. D Keep flammables away from work area. Do not touch or handle induction head/coil during operation un- Do not locate unit on, over, or near combustible surfaces.

  • Page 9: California Proposition 65 Warnings

    READ INSTRUCTIONS. BATTERY EXPLOSION can injure. D Read and follow all labels and the Owner’s D Do not use induction equipment to charge bat- Manual carefully before installing, operating, or teries or jump start vehicles unless it has a bat- servicing unit.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION ihom 2015−09fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    les consommables, les produits de refroidissement, les dégraisseurs, Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace les flux et les métaux. d’étincelles incandescentes ni de flammes. Travailler dans un espace fermé seulement s’il est bien ventilé ou en Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

  • Page 12: Proposition Californienne 65 Avertissements

    Effectuer régulièrement le contrôle et l’entretien de l’installation. LES CHARGES ÉLECTROSTATIQUES Maintenir soigneusement fermés les portes et les panneaux des peuvent endommager les circuits im- sources de haute fréquence. primés. LIRE LES INSTRUCTIONS. D Établir la connexion avec la barrette de terre D Lire et appliquer les instructions sur les AVANT de manipuler des cartes ou des pièces.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Miscellaneous Symbols And Definitions Cursor Button Increase Button Decrease Button 3-2. WEEE 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 collec- tion facility.

  • Page 14: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Unit Specifications Rated Output @ 70° F (21° C) 300 Amps At 100% Duty Cycle 600 ° F (315 ° C)* Maximum Workpiece Preheat Temperature: Minimum Cooling Flow Rate Requirements .30 gpm (1.1 lpm) Cooler ProHeat Heavy Duty Induction Cooler (Coolant 043 810)** *NOTICE - Part temperatures above 6005 F (3155 C) may damage the Rolling Inductor and/or shorten its life.

  • Page 15: Environmental Specifications

    Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç NOTICE −The Miller ProHeat 35 Rolling Inductor is rated for operation between 14° F and 140° F (−10° C to 60° C). For operation at -40° F to 14°...

  • Page 16: Section 5 − Power Source/System Setup

    SECTION 5 − POWER SOURCE/SYSTEM SETUP 5-1. Coolant Hose Connections To Single Output Cable Single Liquid−Cooled Output Connection Cooler 804 435-A Power Source/Cooler Assembly Connect quick-connect fitting on both To remove coolant hoses, grasp black ring coolant hoses from cooler to output cable on coolant hose fitting and pull away from Rolling Inductor Output Cable fittings by pushing coolant hose fitting onto...

  • Page 17: Coolant Hose Connections To Dual Output Cables With 300993 Heat Exchanger

    5-3. Coolant Hose Connections To Dual Output Cables With 300993 Heat Exchanger NOTICE −Incorrect Coolant Con- nections can damage acces- sories. Ensure both accessories are in the coolant loop. Coolant Hose Routing From Cooler Out EXT In EXT Out Cooler Return EXT OUT COOLER OUT COOLER RETURN...

  • Page 18: Mounting Arm To Stand

    5-5. Mounting Arm To Stand Customer supplied pipe stand must be capa- ble of maintaining an upright position with- out tipping with mounting arm, Rolling In- ductor, and accessories installed. Do not step or stand on mounting arm or pipe stand.

  • Page 19: Installing Accessory Cables Into Cable Sleeve

    5-6. Installing Accessory Cables Into Cable Sleeve Cable Sleeve TC Extension Cable Travel Sensor Cable Pneumatic Tubing Assembly IR Extension Cable Alignment Tabs Lay the TC extension cable and sleeve assembly out flat. Unzip the cable sleeve. Position items in the cable sleeve at the approximate di- mensions shown on the Rolling Inductor side of the drawing.

  • Page 20: Mounting Travel Sensor Assembly To The Rolling Inductor

    Micro board is less than 1.28. The cur- rent software revision levels are shown on the front panel display on the ProHeat 35 when it is first turned on. To update soft- ware, contact Miller Service @ www.PW- PService@MillerWelds.com. Ref. 262 417-A OM-261823 Page 14...

  • Page 21: Attaching Quick-Connect Drain Fittings To Air Filter-Regulator Assy

    5-9. Attaching Quick-Connect Drain Fittings To Air Filter-Regulator Assy Air Filter-Regulator Assembly Quick-Connect Fittings Attach supplied quick-connect fit- tings to the bottom of the air fil- ter-regulator assembly. Fittings should be finger-tight only. Do not over-tighten. Pressure Setting Knob NOTICE −Pressure is factory set to 4 psi (0.28 bar) to achieve .53 −...

  • Page 22: Air Filter-Regulator Assembly Input And Output Connections

    5-11. Air Filter-Regulator Assembly Input And Output Connections Air Filter-Regulator Assembly Filter-Regulator assembly showing drain fittings and hose installation. Air Inlet Fitting Install customer supplied (1/4 in. NPT) fitting here. Air-Splitter Use air-splitter when using two Rolling Inductors. Pneumatic tubing to IR assembly.

  • Page 23: Connecting Ir Connection Box To Power Source

    5-13. Connecting IR Connection Box To Power Source Connection Box Plug connection box into th thermocouple inputs on the front panel of the power source. 14-Pin Cable Connect 14-pin cable on connection box to the lower 14-pin connector on the back of the power source.

  • Page 24: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Power Source/System Setup See power source Owner’s Manual for complete instructions on operating the power source. Connect Rolling Inductor to power source before turning it on. 6-1-1 Rolling Inductor—Manual Or Temperature Control Mode NOTICE −When using a Rolling Inductor, infrared temperature measurement and travel detection are highly recommended. The Rolling Inductor induces up to 20 kW into a small area, which can quickly heat a part to over 6005 F (3155 C) if it is not moving fast enough.
  • Page 25 When using two Rolling Inductors, Two IR sensors can be used at the same time. Workpieces should be the same size and material when using two Rolling Inductors on one power source. NOTICE −TC5 and TC6 connect to the Rolling Inductor internal thermocouple which monitors internal Rolling Inductor core temperatures. Measure workpiece temperature with temperature crayons, infrared sensors, or contact thermocouples placed within two inches of the Rolling Induc- tor.

  • Page 26: Temp Control Mode Using Ir Device(S)

    6-1-2 Temp Control Mode Using IR Device(s) IR sensors are often designed for a specific temperature and emissivity range. The ProHeat 35 with Operator Interface software revision 1.28 enables temperature control with the Rolling Inductor. To verify software revision levels, press the Run Status and Parameters buttons simultaneously for 10 seconds to display the software revision. Operator Interface .

  • Page 27: Temperature Feedback Using An Ir Device

    6-2. Temperature Feedback Using An IR Device Definitions: Infrared Radiation (IR) - Radiation that has a wavelength between the red end of the visible light spectrum and microwaves (approx. 800nm to 1mm). It is emitted in particular by heated objects and can be used to determine temperature. Emissivity - A dimensionless quantity describing the efficiency with which a material radiates infrared energy.

  • Page 28: Shielding Of The Ir Cup

    6-4. Shielding Of The IR Cup NOTICE −When welding near an IR sensor, a 1.5 in. Conduit coupler and short section of conduit can be added to help guard from weld spat- ter and smoke. Leave a gap at the Leave Gap At Top Of top of the coupler to allow IR cooling air to ventilate.
  • Page 29 The ProHeat 35 can restrict the maxi- This Chart Depicts The Maximum KW/IPM When Travel Detect Is Set To On mum KW output to the Rolling Inductor when a Travel Detect is utilized. Two Rolling Inductors It is recommended to test part temperature at various travel speeds to ensure the de- sired heat input rate.

  • Page 30: Single Heating Device Arrangement (Shown Without Accessories) And Duty Cycle

    NOTICE −A single Rolling Inductor ar- NOTICE −Only use the Rolling Inductor rangement requires a thermocouple exten- with a Miller ProHeat power source. sion cable, and a Rolling Inductor connec- Do not touch or handle induction ted to a power source.

  • Page 31: Two Heating Devices Arrangement (Shown Without Accessories) And Duty Cycle

    NOTICE −Only use the Rolling Inductor connecting to the Rolling Inductor output power of 35 KW at 100% duty cycle. with a Miller ProHeat power source. must be grounded 3-Prong cables. When running two Rolling Inductors off a single power source, each inductor can Ensure all four wheels are touching the achieve approximately 17.5 KW at 280A.

  • Page 32: Connection Box Label

    6-8. Connection Box Label Connection Box Connection Box Label Make IR connection here when us- ing one Rolling Inductor. Make TC connection here when us- ing one Rolling Inductor. Make an IR connection here when using two Rolling Inductors. Make TC connection here when us- ing two Rolling Inductors.

  • Page 33: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Before Check Rolling Inductor and all Check wearplate for cracks,...

  • Page 34: Infrared Sensor Troubleshooting Guide

    7-4. Infrared Sensor Troubleshooting Guide Problem Cause Potential Solution Infrared sensor is connected but Verify settings on ProHeat are set for IR 4−20 mA, and temp range is temperature is not in range. set to 212°F−752°F (100°C−400°C) if infrared sensor is attached. Verify settings on ProHeat are set for K TC if thermocouple measuring device is attached.

  • Page 35: Replacing The Rolling Inductor Wearplate

    7-6. Replacing The Rolling Inductor Wearplate Disconnect power before maintaining. T25 Torx Head Screw Travel Sensor Bracket Side Panel Assembly Wearplate Rolling Inductor Insulation With Rolling Inductor set on its side, remove and retain screws from side panel assembly. Set Travel Sensor bracket and side panel assembly aside.

  • Page 36: Quartz Window Maintenance

    7-8. Quartz Window Maintenance Quartz Window Retaining Ring NOTICE − Window must be kept clean. Remove dust and foreign matter with compressed air. Clean window with 91percent isopropyl alcohol. Do not use cleaners that leave a film. Replace if scratched, chipped, cracked, or if contaminat- ed with weld spatter.

  • Page 37: Section 8 − Eletrical Diagrams

    SECTION 8 − ELETRICAL DIAGRAMS 8-1. Travel Sensor Circuit Diagram 271 170-C 8-2. IR Sensor Circuit Diagram 271 253-B OM-261823 Page 31...

  • Page 38: Connection Box Circuit Diagram

    8-3. Connection Box Circuit Diagram 267 753-E OM-261823 Page 32...
  • Page 39 Notes OM-261823 Page 33...

  • Page 40: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Ref. 263 983-C Figure 9-1. Rolling Inductor Assembly OM-261823 Page 34...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Rolling Inductor Assembly ....262163 Plate, Side W/Pems Rolling Inductor ....... .
  • Page 42 Hardware is common and not available unless listed. 265 916-F Figure 9-2. IR TC Control Box OM-261823 Page 36...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 9-2. IR TC Control Box ....268033 Label, IR Connection Box .........
  • Page 44 Hardware is common and not available unless listed. 264 092-B Figure 9-3. Mounting Arm Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-3. Mounting Arm Assembly ....263529 Plate, Swivel Induction Arm .
  • Page 45 Hardware is common and not available unless listed. 266 226-B Figure 9-4. Travel Sensor Assembly w/Mounting Bracket Item Dia. Part Mkgs. Description Quantity Figure 9-4. Travel Sensor Assembly w/Mounting Bracket ....266229 O-Ring, 3.350 ID X 3.770 OD Silicone .
  • Page 46 Hardware is common and not available unless listed. 265 181-D Figure 9-5. IR Assembly w/Mounting Bracket Item Dia. Part Mkgs. Description Quantity Figure 9-5. IR Assembly w/Mounting Bracket ....265076 Sensor, Temperature IR Assembly .
  • Page 47 Hardware is common and not available unless listed. 265149-C Figure 9-6. Regulator−Filter Air/Oil Separator Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-6. Regulator−Filter Air/Oil Separator Assembly ....265146 Filter−Reg, 1/4 Npt 5 Micron 0−30psi Auto Drain W/N .
  • Page 48 Hardware is common and not available unless listed. Items in Figure 9-7 are shown for parts identification. They are not available as a complete assembly. 265156-C Figure 9-7. Cables And Hoses Item Dia. Part Mkgs. Description Quantity Figure 9-7. Cables And Hoses .
  • Page 49 Hardware is common and not available unless listed. 270 112-B Figure 9-8. Rolling Inductor Stand Item Dia. Part Mkgs. Description Quantity Figure 9-8. Rolling Inductor Stand ....269173 Pin, Quick Release .375 Dia X 1.300 Usable LG .
  • Page 51 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 52 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

This manual is also suitable for:

301149301183Proheat rolling inductorProheat 35 rolling inductor

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