Miller Non-CE Owner's Manual

ProHeat 35ProcessesDescriptionInduction Heating Power SourceInduction HeatingOM-222 166N 2009−03File: Induction HeatingVisit our website atwww.MillerW

OM-222 166 Page 4SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONihom _2007−04freSe protéger, ainsi que toute autre personne travaillant sur

OM-222 166 Page 5D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée auniveau de l’arc pour l’évacuation des fumées et des gaz.D S

OM-222 166 Page 6LE RAYONNEMENT HAUTE FRÉ-QUENCE (HF) risque de provoquerdes interférences.D Le rayonnement haute fréquence (HF) peutprovoquer des int

OM-222 166 Page 7SECTION 3 − DEFINITIONS3-1. Warning Label DefinitionsWarning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric

OM-222 166 Page 83-2. Warning Label Definitions (Continued)1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Electric shock fro

OM-222 166 Page 93-3. WEEE Label (For Products Sold Within The EU)Do not discard product (where ap-plicable) with general waste.Reuse or recycle Waste

OM-222 166 Page 10SECTION 4 − INSTALLATION4-1. Serial Number and Rating Label LocationThe serial number and rating information for the power source is

OM-222 166 Page 114-4. Tipping! Do not move or operate unitwhere it could tip.4-5. Electrical Service GuideFailure to follow these electrical service

OM-222 166 Page 124-6. Connecting 3-Phase Input Power For 460/575 Volt Models803 994-C3/8 inTools Needed:! Installation must meet all Nationaland Loca

OM-222 166 Page 13Ref. 804 430-ATools Needed:4-7. Connecting 3-Phase Input Power For 400/460 Volt IEC And CE Models3/8 in! Installation must meet all

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-222 166 Page 14Ref. 803 993-C / Ref. 804 217-A4-8. Power Source Output Connections1 Output Connector 12 Output Connector 23 Protective Plug4 Air-Co

OM-222 166 Page 15803 993-C4-9. Remote 14 Receptacle RC14 Information and Connections1 Plug2 Threaded Collar3 Keyway4 Remote 14 Receptacle RC14(See Se

OM-222 166 Page 16803 993-C4-11. Temperature Recorder Receptacle RC9 Information And Connections1 Plug2 Threaded Collar3 Temperature RecorderReceptacl

OM-222 166 Page 17803 994-B / Ref. 801 826-C / Ref. 801 828-C4-13. Secondary Insulation ProtectionSecondary insulation protectioncircuitry automatical

OM-222 166 Page 18803 993-C4-14. 115 Volt AC Duplex Receptacle And Supplementary Protector1 115 VAC 2.5 A Single-PhaseAC Receptacle RC12 Supplementar

OM-222 166 Page 199. The following describes the thermocouple routing from work to power source.S Type K thermocouple wire (two wire) is attached dire

OM-222 166 Page 204-16. Attaching Welded Thermocouples. Do NOT weld thermocouples while connected to power source.1. Attach thermocouples using a port

OM-222 166 Page 214-17. Using Contact ThermocouplesThe welded thermocouples discussed previously can be used for preheating or stress relieving. As an

OM-222 166 Page 22SECTION 5 − COMPONENTS AND CONTROLS5-1. Controls. When a control panel button is pushedthe yellow lamp lights to indicate ac-tivatio

OM-222 166 Page 23SECTION 6 − SETUP AND OPERATION6-1. Safety EquipmentWear the following duringoperation:1 Dry, Insulating Gloves2 Safety Glasses With

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol U

OM-222 166 Page 24Possible selections:Degree Units: °F / °CTolerance: ±5 to 99 in °F (±3 to 55 in °C)Backlight: Yes / NoInput Type: K TCControl Mo

OM-222 166 Page 256-4. ProgrammingProgramming allows the operator to setup a program for a particular heating process. The selections available are Te

OM-222 166 Page 26Mode...: Bake−OutControl TC:>1Soak Temp.: 600 Soak Time: 01:00:00Cool Temp.: 200 Cool Rate: 600 _/HrBake-Out ScreenThe de

OM-222 166 Page 27Use the Cursor button to move the cursor to the desired selection (Ramp Temperature, Ramp Rate, Soak Temperature, or Soak Time),an

OM-222 166 Page 28The default position of the cursor is next to Segment. Press the Increase or Decrease button to increase or decrease thesegment

OM-222 166 Page 29Use the Cursor button to move the cursor to the Temperature or Ramp Rate position and use the Increase or Decrease button to set

OM-222 166 Page 30A custom program can contain up to 10 segments. To view Program parameters, position the cursor at segment and use the Increase or

OM-222 166 Page 31Mode...: Custom ProgramSegment...: 5Type...: EndControl TC.: 1Custom Program ScreenEnd segment ends the heat treat cycle.

OM-222 166 Page 32Mode...: TimedSegment: 1Type...:>Power LevelPower..: 0.0 KW Time: 00:00:00The default position of the cursor is next to P

OM-222 166 Page 336-5-2. Manual ControlMode...: Manual TC5: 77Power...: 0.0 KW TC6: 77Countdown: −−:−−:−−Status...: S

TABLE OF CONTENTS6-5. Run Status 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-222 166 Page 34Power...: 0.0 KW TC5: 77Current..: 0 A TC6: 77Voltage..: 0 VFrequency: 4.5 KHzParameters Scree

OM-222 166 Page 35S The Stop button indicator LED illuminates to indicate no heating cycle is in process.S The temperature displays indicate actual

OM-222 166 Page 36Pressing the Hold button will activate the hold function while running a temperature controlled program. While in the hold mode, t

OM-222 166 Page 376-9. System Operating CharacteristicsThe power source delivers a high-frequency alternating current output that energizes the coil c

OM-222 166 Page 38SECTION 7 − MAINTENANCE7-1. Routine Maintenance! Disconnect power before maintaining.. Maintain more oftenduring severe conditions.n

OM-222 166 Page 397-2. Calibration Verification Equipment1 Thermocoupler CalibratorSuggested calibrator from Fluke item 714or equivalent.2 Type K Mini

OM-222 166 Page 402. Turn ProHeat 35 power switch off.3. Have qualified person disconnect primary power.4. Remove precision DVM and TC calibrator.5. C

OM-222 166 Page 41does hereby certify the above instrument was calibrated against standardsand meets or exceeds all published specifications.The accur

OM-222 166 Page 42does hereby certify the above instrument was calibrated against standardsand meets or exceeds all published specifications.The accur

OM-222 166 Page 43SECTION 8 − SAFETY PRECAUTIONS FOR SERVICINGProtect yourself and others from injury — read and follow these precautions.8-1. Symbol

243165DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer St

OM-222 166 Page 44MOVING PARTS can cause injury.D Keep away from moving parts such as fans.D Have only qualified persons remove doors,panels, covers,

OM-222 166 Page 45SECTION 9 − DIAGNOSTICS & TROUBLESHOOTINGThe ProHeat 35 power source has on-board capabilities to aid in troubleshooting problem

OM-222 166 Page 469-2. Limit ConditionsA limit condition indicates that the system has encountered an open thermocouple or is outside the range of its

OM-222 166 Page 47Limit Condition Additional InformationL11: Coolant Overtemp Limit Check coolant flow and levelClean coolant filters and heat exchang

OM-222 166 Page 48Fault Condition Additional InformationF67: Over Frequency Fault Verify heating cable properly wrappedVerify material being heated is

OM-222 166 Page 49S PLUG − for a protective plugS OPEN − no cable or plug in placeClntFR − This is the coolant flow rate (in GPM) from the cooler on a

OM-222 166 Page 509-7. Removing Wrapper and Measuring Input Capacitor Voltage! 900 Volts dc can be presenton the capacitor bus andsignificant DC volta

OM-222 166 Page 519-8. Blowing Out Inside Of Unit! Turn Off welding powersource and disconnect inputpower.! Remove wrapper and besure input capacitors

OM-222 166 Page 52SECTION 10 − ELECTRICAL DIAGRAMFigure 10-1. Circuit Diagram

OM-222 166 Page 53218 057-H

OM-222 166 Page 54SECTION 11 − PARTS LIST. Hardware is common andnot available unless listed.Figure 11-1. WrappersRef. 804 218-D1356781191011See Figur

OM-222 166 Page 55. Hardware is common andnot available unless listed.Figure 11-2. Front Panel804 219-A12311812451367910QuantityDescriptionPartNo.Dia.

OM-222 166 Page 56. Hardware is common andnot available unless listed.Figure 11-3. Rear Panel804 220-A1381164291012135147QuantityDescriptionPartNo.Dia

OM-222 166 Page 57. Hardware is common andnot available unless listed.Figure 11-4. Base w/Components804 221-D1144213761465910831231516QuantityDescript

OM-222 166 Page 58. Hardware is common andnot available unless listed.Figure 11-5. Top Windtunnel804 222-A135287111091312614154See Figure 11-616Quanti

OM-222 166 Page 59. Hardware is common andnot available unless listed.Figure 11-6. Capacitor Assembly804 223-A1234QuantityDescriptionPartNo.Dia.Mkgs.I

OM-222 166 Page 60. Hardware is common andnot available unless listed.804 224-E1675416123109118181314151721920Figure 11-7. Right WindtunnelQuantityDes

OM-222 166 Page 61QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-7. Right Windtunnel (Continued)17 229 728 STRAP, connecting 4. . . . . . . . .

OM-222 166 Page 62. Hardware is common andnot available unless listed.804 431-E21675414310911817162218131912201521Figure 11-8. Right Windtunnel (400 V

OM-222 166 Page 63QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-8. Right Windtunnel (400 V Model Only) (Continued)17 PC6 216 262 CIRCUIT CARD AS

OM-222 166 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGihom _2007−04Protect yourself and others from injury — read and follow these precau

OM-222 166 Page 64. Hardware is common andnot available unless listed.Figure 11-9. Left Windtunnel804 225-A212613741115935148110QuantityDescriptionPar

OM-222 166 Page 65QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-9. Left Windtunnel (Continued)PLG16,. . . . . . . 121,122 131 054 HOUSING RCPT+S

OM-222 166 Page 66. Hardware is common andnot available unless listed.Figure 11-10. Hermaphroditic Blank Plug Assy804 300-A123453467819QuantityDescrip

OM-222 166 Page 67804 324-A12345678Figure 11-11. Air−Cooled Output Extension CablesDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-11. Air−Cooled Output E

OM-222 166 Page 6816579108112346543804 411-AFigure 11-12. Liquid−Cooled Output Extension CablesDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-12. Liquid−

OM-222 166 Page 692314566804 404-AFigure 11-13. Heating CablesDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-13. Heating Cables (300 045, 300 046, 300 04

OM-222 166 Page 70201 432-G1Figure 11-14. Quick Connect To Quick Connect HoseDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-14. Quick Connect To Quick Co

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2009−01Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Miller Electric Mfg. Co. 2009−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer

OM-222 166 Page 2FIRE OR EXPLOSION hazard.D Do not overheat parts.D Watch for fire; keep extinguisher nearby.D Keep flammables away from work area.D D

OM-222 166 Page 31-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document