Miller 4:1 IMPEDANCE MATCHING TRANSFORMER 043276 Owner's manual

Brand: Miller

Model: 4:1 IMPEDANCE MATCHING TRANSFORMER 043276

Type: Owner's manual

This manual is also suitable for

LC443361

Miller 4:1 IMPEDANCE MATCHING TRANSFORMER 043276

Compatible with power sources with a 10 to 50 kHz output frequency range, the Miller 4:1 Impedance Matching Transformer 043276 is ideal for a variety of induction heating applications. With a 70 kVA rating and a 1.3 qt/min (1.2 L/min) minimum coolant flow rate, this transformer provides efficient and reliable performance.

Key Features:

4:1 turns ratio for step-down transformer applications
Reflective impedance approximately 16 times coil impedance
70% duty cycle at rated primary amperage
Built-in flow indicator for checking coolant flow

Miller 4:1 IMPEDANCE MATCHING TRANSFORMER 043276

Key Features:

4:1 turns ratio for step-down transformer applications
Reflective impedance approximately 16 times coil impedance
70% duty cycle at rated primary amperage
Built-in flow indicator for checking coolant flow

OWNER’S MANUAL

February 2003 FORM: OM-178 715C

4:1 Impedance Matching Transformer 043 276

1. Specifications

4:1 Turns Ratio; Step Down Transformer

10 To 50 kHz Output Frequency Range

Reflective Impedance is approximately 16 Times Coil Impedance

70% Duty Cycle At Rated Primary Amperage

1.3 qt/min (1.2 L/min) Minimum Coolant Flow Rate (Built-In Flow Indicator For Checking Coolant Flow)

70 kVA Rating

Length: 12 in (305 mm); Width: 8-3/4 in (222 mm); Height: 6-1/4 in (159 mm)

801 415-C

Weight: Net 18-3/4 lb (8.5 kg)

2. Safety Symbol Definitions

Warning! Watch Out! There are possible hazards as shown in the adjoining symbols.

Beware of electric shock from wiring. Keep all panels and covers closed.

Induction heating can cause fire. Move flammables away. Do not overheat parts and adhesive. Watch for fire; keep extinguisher

nearby.

Breathing fumes and gases from induction heating operations can harm your health. Properly ventilate work area. Read Material

Safety Data Sheets (MSDS’s) and manufacturer’s instructions for materials used.

Hot parts can cause burns. Induction heating makes parts very hot – let them cool before touching. Do not touch or handle in-

duction head during operation. Keep metal jewelry and other metal personal items away from head during operation.

Wear safety glasses with side shields.

Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the

directions. For INDUCTION HEATING SAFETY and EMF information, read power source manual.

Beware of moving parts. Keep guards and panels in place, covers closed, and hands away from moving parts.

Recycle or dispose of used liquids in an environmentally safe way. This is especially true for engine fluids such as drain oil and

used coolant; also important for coolant from cooling systems.

OM-178 715 Page 2

3. Connecting Transformer To Power Source

ST-801 049

1 Output Receptacle RC15

2 Plug From Transformer

3 Threaded Collar

Receptacle RC15 is a 4-socket

receptacle.

To connect to receptacle, align

keyway, insert plug, and tighten

threaded collar.

4 14-Socket Receptacle

Power Source Rear Panel

4. Connecting Coolant Lines To Transformer

801 415-C / Ref. S-0446-A / S-0628-A

1 Coolant In Fitting

2 Coolant Out Fitting

Connect lines from coolant system to

correct fittings on transformer.

Install induction coil using the supplied

O-rings (5/16 in ID x 7/16 in OD or

#14 – 1/2 in ID x 5/8 in OD) and customer

supplied 10-32 bolts.

3 Flow Indicator

4 Flow Switch Plug And Receptacle

5 Pendant Receptacle RC4

Connect flow switch receptacle to pins C

and D at receptacle RC4 on Pendant.

Turn on coolant flow and power source,

and check for any coolant leaks. Check

coolant flow at flow indicator on

transformer.

If power source contactor does not

energize, flow switch is not closed. Check

coolant system for proper flow through

transformer.

Tools Needed:

5. Operation

Install & Connect

Power Source

Put On

Personal Safety

Equipment

Set

Controls

Turn On

Power

Switch

Wait

10 Seconds

Unit Ready

To Heat

Turn On

Coolant Supply

Position Work

Near

Heat Station

Install & Connect

Transformer &

Install & Connect

Coolant Supply

Induction Coil

OM-178 715 Page 3

6. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Clean And

Tighten Output

Connection

(see Section 3)

Water Hose

Replace

Cracked

Parts

Output

Cord

6 Months

Replace

Unreadable

Labels

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly

7. Troubleshooting

Trouble Remedy

No heat output. Connect power source to proper input voltage or check for low line voltage (see power source Owner’s

Manual).

Transformer coolant flow switch not closed. Check coolant system for proper flow through transformer.

No heat output; fan motor continues to

run.

Tuning capacitor cover safety interlock switch open (see power source Owner’s Manual).

Secure transformer plug in power source receptacle (see Section 3).

Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled

(see power source Owner’s Manual).

Low heat output. Check tuning of induction heating output system (see Section 8).

8. Tuning Chart

CAUTION

ENERGIZING CONTACTOR WITHOUT ALL 3 TUNING CAPACITORS IN OUTPUT CIRCUIT will damage power

source.

• DO NOT operate power source without all 3 tuning capacitors in output circuit.

Voltage* Current (Amperage)* Frequency (KHz) Corrective Action

High Low Low Lower inductance or decrease matching transformer turns ratio

High Low High Add capacitance

High Low Mid-Range Decrease matching transformer turns ratio and add capacitance

Low High Low Lower capacitance

Low High High Increase matching transformer turns ratio, or lower capacitance

and increase inductance

Low High Mid-Range Increase matching transformer turns ratio and lower capacitance

*High voltage > 300 V rms; Low voltage < 200 V rms; Operating current range: 0 to 210 A rms

OM-178 715 Page 4

9. Parts List

. Hardware is common and

not available unless listed.

*12

*Fittings must be removed from old flow

switch and installed in replacement switch.

801 415-C

Figure 9-1. 4:1 Impedance Matching Transformer

Description

Part

No.

Dia.

Mkgs.

043 276

Item

No.

Figure 9-1. Impedance Matching Transformer

Quanti

1 186 003 INDICATOR, flow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 178 191 LABEL, coolant in/coolant out 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 196 750 COVER, induction head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 145 642 CONNECTOR, tubing 1.000 w/1.000 npt str w/o nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CINCH, S–202–B socket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CINCH, P–202–CCT plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 145 643 CONDUIT, non metallic flexible 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 043 995 WIRE, litz 4AWG rnd 43, 750 cma 5x5x5x14 teflon red 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 167 938 ADAPTER, amphenol/heyco 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 167 722 CONNECTOR, circ ms/met 4 pin size 36 plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 O–RING (#14 – 1/2 in ID x 5/8 in OD) or. . . . . . . . . . . . . . . . . . . . . . . .

11 O–RING (5/16 in ID x 7/16 in OD) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 GEMS flow switch #122353 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 178 192 LABEL, warning induction heating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .