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Miller ProHeat 35 User Manual

Miller ProHeat 35
98 pages
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ProHeat 35
Processes
Description
Induction Heating Power Source
Induction Heating
OM-222166AH 2016−12
File: Induction Heating
Visit our website at
www.MillerWelds.com
CE And Non CE Models
[
(For Stock Nos. 907271, 907298, and 907432)

Table of Contents

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Miller ProHeat 35 Specifications

General IconGeneral
Power SourceElectric
Weight27 lb (12.3 kg)
Dimensions18 in x 12 in x 12 in (457 mm x 305 mm x 305 mm)
Input Frequency50/60 Hz
Output Power35 kW
Fuel TypeElectric

Summary

Safety Precautions

Symbol Usage

Explains hazard symbols used in the manual for safety.

Induction Heating Hazards

Details hazards associated with induction heating operations and necessary precautions.

Additional Safety Symbols and Precautions

Details additional symbols for installation, operation, maintenance, and specific hazards.

California Proposition 65 Warnings

Information on chemicals known to cause birth defects or cancer.

Principal Safety Standards

Lists key safety standards and where to obtain them.

EMF Information

Explains electromagnetic fields and their potential interference with medical implants.

General Safety Instructions and Warnings

Provides essential instructions for safe operation, maintenance, and handling.

Definitions and Safety Symbols

Additional Safety Symbols

Explains additional safety symbols, some specific to CE products.

Miscellaneous Symbols and Definitions

Provides definitions for various symbols used in the manual, including electrical and operational terms.

Specifications

Serial Number and Rating Label Location

Details the location of serial number and rating labels on the machine.

Technical Specifications

Lists output frequency, rated output, required inductive reactance, and input amperage.

Environmental Specifications

Details IP Rating and Electromagnetic Compatibility (EMC) requirements.

Installation Guide

Selecting Installation Location

Provides guidelines for choosing a suitable location for the unit, considering airflow and safety.

Dimensions and Weights

Lists the physical dimensions and weight of the equipment.

Electrical Service Requirements

Details electrical service requirements, including voltage, amperage, and conductor sizing.

Connecting 3-Phase Input Power (460/575V)

Step-by-step instructions for connecting 460/575 volt 3-phase input power.

Connecting 3-Phase Input Power (400/460V IEC/CE)

Instructions for connecting 400/460 volt 3-phase input power for IEC and CE models.

Coolant Jumper Connections

Details how to make coolant jumper connections for system configuration.

Power Source Output Connections

Guides on connecting output cables for single, dual, air-cooled, and liquid-cooled configurations.

Remote Control Connections

Information and pinout for the Remote 14 Receptacle (RC14) for remote control.

Temperature Recorder Connections

Details the RC9 receptacle and socket information for temperature recording.

Secondary Insulation Protection

Explains the secondary insulation protection feature and its operation.

Auxiliary Power and Thermocouple Placement

Describes the 115V AC receptacle and how to locate thermocouples for accurate heating.

Thermocouple Attachment Methods

Details methods for attaching welded and contact thermocouple sensors for temperature measurement.

Non-Contact Temperature Sensors

Guidance on locating and using non-contact temperature sensors for optimal control.

Components and Controls Overview

Front Panel Controls

Identifies and describes the function of each control button and indicator on the front panel.

Setup and Operation

Required Safety Equipment

Lists essential safety equipment required for operating the unit.

System Description and Configuration

Explains how the system configures itself based on connected heating devices.

System Guidelines and Setup

Provides guidelines for using multiple systems and initial system setup procedures.

Programming and Configuration Settings

Details how to reset to factory defaults and program heating processes.

Temperature-Based Control Programming

Explains programming four temperature-based processes: Preheat, Bake-Out, PWHT, Custom Program.

Heating Process Programming Details

Details programming for Bake-Out process, including temperature, soak time, and cool rate.

Post-Weld Heat Treat (PWHT) Programming

Describes programming for PWHT, including ramp and soak parameters.

PWHT Operation and Custom Programs

Explains PWHT operation and how to create custom heating programs.

Alternative Control Modes

Details operation modes: Remote Control, Power vs Time Control, and Manual Control.

Manual and Rolling Inductor Control

Explains Manual Control and Rolling Inductor modes, including travel detection.

Monitoring Heating Processes

Describes Run Status screens for monitoring Preheat, Bake-Out, PWHT, and Custom Programs.

Run Status for Different Control Modes

Details Run Status screens for Manual, Remote, and Power vs Time control modes.

System Parameters and Cooler Operation

Explains system parameters and how to operate the cooler unit.

Real-Time Operation and System Checks

Describes the system check routine upon power-up and real-time operation.

System Operating Characteristics

Details power source output characteristics based on configuration and coil type.

Rolling Inductor Output Characteristics

Describes Rolling Inductor output amperage vs. heating time and travel speed.

Routine Maintenance Schedule

Daily Maintenance Checks

Daily visual inspections of cords, cables, and labels.

Periodic Maintenance Checks

Maintenance checks performed every 3 months, 6 months, and annually.

Calibration Verification

Calibration Verification Equipment

Lists the equipment required for calibration verification.

Calibration Verification Procedure

Step-by-step guide for performing calibration verification and TC input/output checks.

Finishing Calibration Procedure

Steps to complete after calibration verification, including label placement.

Safety Precautions for Servicing

Symbol Usage for Servicing

Explains symbols used to indicate safety instructions during servicing.

Servicing Hazards and Precautions

Details hazards like electric shock, fire, flying metal, and induction heating burns during servicing.

Servicing Safety Warnings and Guidelines

Covers falling equipment, overuse, HF radiation, EMF, and general servicing instructions.

Diagnostics and Troubleshooting

Operator Interface Indicators

Explains the Fault LED, Limit LED, and LCD display for diagnostics.

Understanding Limit Conditions

Describes limit conditions, how they are indicated, and options for resolution.

Limit Condition Codes and Information

Lists limit condition codes and provides additional information for troubleshooting.

Identifying Fault Conditions

Explains fault conditions, their indications, and system response.

Fault Condition Codes and Solutions

Lists fault condition codes and provides additional information or required service.

Sensor and System Diagnostics

Troubleshooting guide for infrared sensors and description of system diagnostic screens.

System Diagnostic Screen Details

Explains parameters shown in system diagnostic screens, including voltage, temperature, and coolant status.

Firmware Versions and Compatibility

Lists firmware versions, PC board names, and compatibility information.

Capacitor Voltage Measurement and Safety

Procedure for safely measuring input capacitor voltage after power disconnection.

Cleaning Internal Components

Instructions for safely blowing out dust and debris from inside the unit.

Electrical Diagram

Parts List

Wrapper Components

Lists parts for the front and side panels, doors, hinges, and fans.

Front and Rear Panel Components

Lists components of the front and rear panels, including receptacles and circuit cards.

Windtunnel Components

Parts list for the right windtunnel assembly for 460-575V models.

Windtunnel Components (400-460V)

Parts list for the right windtunnel assembly for 400-460V models.

Left Windtunnel Components

Parts list for the left windtunnel assembly.

Cable Components

Lists parts for air-cooled output extension cables.

Liquid-Cooled Output Extension Cables

Parts for liquid-cooled output extension cables.

Heating Cables

Lists components for heating cables.

Quick Connect Hose Components

Parts list for the quick connect to quick connect hose assembly.

Induction Blanket and Sleeve Components

Lists various sizes and types of induction blanket and sleeve components.

Rolling Inductor Assembly Components

Lists all components for the complete rolling inductor assembly.

Rolling Inductor Mounting Arm Components

Parts for the rolling inductor mounting arm assembly.

Rolling Inductor Stand Components

Lists components for the rolling inductor stand assembly.

Travel Sensor Assembly Components

Lists components for the travel sensor assembly with mounting bracket.

IR Assembly Components

Parts list for the IR assembly with mounting bracket.

IR TC Control Box Components

Parts for the IR TC control box assembly.

Regulator-Filter Air/Oil Separator Components

Lists parts for the regulator-filter air/oil separator assembly.

Miller True Blue Warranty

Owner's Record and Service Information

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