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Miller IHC Owner's Manual

Miller IHC Owner's Manual

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OM-148 367
November 1997
Processes
Induction Heating
Description
Induction Heating Control
IHC

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  • Page 1 OM-148 367 November 1997 Processes Induction Heating Description Induction Heating Control Visit our website at www.MillerWelds.com...
  • Page 2 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY FOR INDUCTION HEATING ........1-1.

  • Page 5: Section 1 - Safety For Induction Heating

    SECTION 1 – SAFETY FOR INDUCTION HEATING safety_ihom1 10/96 WARNING INDUCTION HEATING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In heating, as in most jobs, exposure to certain hazards occurs. Heating is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page.

  • Page 6: Additional Installation, Operation, And Maintenance Hazards

    1-1. Additional Installation, Operation, And Maintenance Hazards FALLING EQUIPMENT cause STATIC ELECTRICITY can damage serious personal injury and equipment parts on circuit boards. damage. 1. Put on grounded wrist strap BEFORE handling boards or parts. 1. Use handle and have person of adequate physical strength lift unit.

  • Page 7: Section 1 - Mesures De Securite Pour Le Chauffage Par Induction

    SECTION 1 – MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION safetyihom_fre 9/96 AVERTISSEMENT LE CHAUFFAGE PAR INDUCTION peut être dangereux. 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.

  • Page 8: Dangers Supplémentaires De Mise En Route, De Fonctionnement Et D'entretien

    1-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien LA CHUTE DE MATERIEL peut provoquer UNE UTILISATION INTENSIVE peut provo- des blessures personnelles graves et en- quer un SURCHAUFFEMENT DU MATERIEL. dommager les équipements. 1. Prévoir une période de refroidissement 2.

  • Page 9: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Parameters Time Range Input Power Type Of Type Of Memory Memory Control Control For Each For Each Overall Overall Weight For Each Cord With Input Power Capacity Capability Dimensions Induction Step Plug Head Delay Time Before Heating Each Program Process,...

  • Page 10: Remote Start Switch Connection Requirement

    2-4. Remote Start Switch Connection Requirement A remote maintained contact switch must be connected to the control to start the heating program. Turn Off control and power source. Screw Loosen to open front panel. Remote Control Cable Strip insulation from lead ends. Strain Relief Route cable through strain relief.

  • Page 11: Connecting External Device (Optional)

    2-5. Connecting External Device (Optional) This control may be connected to an external device, such as a fixturing control or programmable logic control. The control can send signals to the external device when a program is running and when a fault exists.

  • Page 12: Connecting Remote Program Selection Device (Optional)

    2-6. Connecting Remote Program Selection Device (Optional) This control may be connected to a remote program selection device. The remote device overrides the front panel controls covered in Sec- tion 3. To connect remote device, proceed as follows: Turn Off control and power source. Interface Board PC1 Pressure Terminal Strip RC23 Pressure Terminal Strip RC22...

  • Page 13: Connecting Input Power

    2-7. Connecting Input Power 115 Volts AC 50/60 Hz Grounded Receptacle Plug From Unit Select extension cord of 18 AWG or larger. ST-150 615 SECTION 3 – PROGRAMMING WARNING ELECTRIC SHOCK can kill. • Do not touch live electrical parts. •...

  • Page 14: Keyed Switch

    3-2. Keyed Switch Keyed Switch Use switch to place control in one of three states of programming. To enter or change a program, place switch in Program position. The program may also be run in this position. To lock out any program changes while running a program, place switch in the Run position.

  • Page 15: Introduction Screens

    3-4. Introduction Screens Keyed Switch Turn On control, and place keyed switch in Program position. Digital Display The screens shown scroll across “M I L L E R ” I N DU C T I O N display. H E A T I NG CO N T RO L L E R P RO G R A M # 1 U S E R EMO T E...

  • Page 16: Increase And Decrease Buttons

    3-6. Increase And Decrease Buttons Increase Button Press button to move to next screen. P RO G R A M # 1 Press Decrease button to move to previous screen. U S E R EMO T E T O S T A R T Blinking Parameter Press Parameter Select button to select a parameter.

  • Page 17: Initial Screens

    3-9. Initial Screens Induction Head # Set between 1 and 8. Initial Time I N I T I A L Defines time head preheats at Initial TI ME 0 0 1 . 0 0 S E C ON D S Power setting.

  • Page 18: Optional Temperature Compensation Screens

    3-12. Optional Temperature Compensation Screens NOTE If control is equipped with Temperature Compensation option, see Section 6. 3-13. Setting Parameters A. Enabled Or Disabled Induction Head H E A D Set program #. See Section 3-5. ( E N A B L E D ) Increase Repeat Until Parameter...
  • Page 19 C. Initial Time And Power I N I T I A L Set parameter in Section 3-13B. TI ME = 0 0 1 . 0 0 S E CO ND S Increase Repeat Until Parameter Parameters Select Set For All Heads I N I T I A L I N I T I A L...

  • Page 20: Dry Run

    F. Final Slope Time Set Head # And Set parameter in F I N A L S L OP E Time As Shown Section 3-13E. In Section 3-13C. TI ME 0 0 1 . 0 0 S E C ON D S Increase G.
  • Page 21 NOTE Make copies of these charts for future use. Program # Program Description Start Initial Final Initial Power Final Delay Slope Slope Head # Time Time Power Time Time Power Time Time Power Program # Program Description Start Initial Final Initial Power Final...

  • Page 22: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Controls See Sections 3-1 thru 3-3 control descriptions. Digital Display Parameter Select Button Keyed Switch Power Switch Decrease-Left Button Increase-Right Button Bottom Panel Ref. ST-151 644-A / ST-151 643 4-2. Safety Equipment Insulating Gloves Safety Glasses With Side Shields Wear dry insulating gloves and safety glasses with side shields.

  • Page 23: Running A Program

    4-4. Running A Program Program Screen Step #1 Select desired program # (see Sec- tion 3-5). Interface Board PC1 P RO G R A M # 1 Receptacle RC20 – Remote U S E R EMO T E T O S T A R T Start Switch Connection Remote start switch must be connected to RC20 (see Section...

  • Page 24: Optional Run Time Indicator And Fault Indicator Operation

    4-5. Optional Run Time Indicator And Fault Indicator Operation Interface Board PC1 Receptacle RC14 – Run Time Indicator Connection Receptacle RC15 – Fault Indicator Connection See Section 2-5 for RC14 and RC15 connections. When initially energizing unit, internal relay connections to RC14 and RC15 are both open.

  • Page 25: Remote Program Selection

    4-6. Remote Program Selection This control may be connected to a remote program selection device (see Section 2-6). The remote device overrides the front panel controls covered in Section 3. To use remote device, proceed as follows: Turn Off control and power source. Logic Board PC2 DIP Switch SW1 Place SW1 position 1 in the Off...

  • Page 26: Section 5 - Teaching Optional Temperature Compensation Program

    SECTION 5 – TEACHING OPTIONAL TEMPERATURE COMPENSATION PROGRAM WARNING ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Turn Off power source during programming. • Keep Key switch in Program position. • Keep all panels, doors, and covers closed and secure during programming. •...

  • Page 27: How To Make Trial Runs

    5-2. How To Make Trial Runs A. Disabling Temperature Compensation Temp Compensation Screen Induction Head # Set between 1 and 8. Example shown selects head #2. The Temperature Compensation T EM P C OM P E N S A T I O N option must be Disabled during the Set parameters trial runs.
  • Page 28 B. Completing Trial #1 Steps For Trial #1 Run Trial #1 At Set Trial #1 Record Trial #1 Note Results Go On To Parameters Trial #1 Of Trial #1 Lower Ambient Parameters Section 5-2C Temperature Below Heating Program (See Section 5-2A) For Trial #2 Parameters For Trial #1 AMB I E N T...

  • Page 29: Calculations Using Trial #1 And #2 Parameters

    C. Completing Trial #2 NOTE Power output in percent and ambient temperature are the only parameters to change between Trial #1 and Trial #2 (see Section 3-13C and Section 5-1). Steps For Trial #2 Run Trial #2 At Set Trial #2 Record Trial #2 Trial #2 Results Set Power Output...

  • Page 30: Entering Values Into Temperature Compensation Program

    5-4. Entering Values Into Temperature Compensation Program T EM P C OM P E N S A T I O N Set parameters, see Section 5. E N A B L E D Repeat Until Values Set For All Heads Increase Repeat To Set Nominal...

  • Page 31: Optional Temperature Compensation Program

    Optional Temperature Compensation Program NOTE Make copies of these charts for future use. Trial #1 ° Ambient Thermocouple, T Start Initial Final Initial Power Final Delay Slope Slope Head # Time Time Power Time Time Power Time Time Power Trial #2 °...

  • Page 32: Section 6 - Maintenance & Troubleshooting

    SECTION 6 – MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Turn Off all power before maintaining. 6 Months 3 Months Blow Out Replace Cracked Vacuum Parts Inside Section Replace Unreadable Labels Ref. ST-150 615 6-2. Warning Screens Warning Memory Is Not Work- ing Screen This screen may appear when turn- ing Power switch On.
  • Page 33 Notes OM-148 367 Page 29...

  • Page 34: Section 7 - Electrical Diagrams

    SECTION 7 – ELECTRICAL DIAGRAMS SC-145 873-C Figure 7-1. Circuit Diagram For Induction Heating Control OM-148 367 Page 30...
  • Page 35 SC-147 692-C Figure 7-2. Wiring Diagram For Induction Heating Control OM-148 367 Page 31...

  • Page 36: Section 8 - Parts List

    SECTION 8 – PARTS LIST Hardware is common and not available unless listed. ST-150 617-B Figure 8-1. Complete Assembly OM-148 367 Page 32...
  • Page 37 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ..... 126 908 . . . BEZEL/FILTER, blue filter ........
  • Page 38 Notes OM-148 367 Page 34...
  • Page 39 Effective January 1, 1997 (Equipment with a serial number preface of “KH” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
  • Page 40 Welding Process Handbooks Contact the Delivering Carrier File a claim for loss or damage during ship- for: ment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  PRINTED IN USA 1997 Miller Electric Mfg. Co.

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