Miller I Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

IH/TC
Processes
Description
OM-193 253C
August 2002
Induction Heating
Single Induction Heating Power Source
Temperature Control
Visit our website at
www.MillerWelds.com
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners 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. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Induction Heating Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 2. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION 3. . . . . . . . . . . .
1-1. Dangers supplémentaires de mise en route, de fonctionnement et dentretien 4. . . . . . . . . . .
1-2. Informations concernant les champs électro-magnétiques (Information EMF) 5. . . . . . . . . . .
PRINCIPALES NORMES DE SÉCURITÉ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. IH/TC Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting To Power Source 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Input 14 Pin Information For Receptacle RC1 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Remote Start/Stop Switch Or IH/PC Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Remote Start/Stop Socket Information For Receptacle RC2 10. . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting External Device 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – PROGRAMMING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Digital Display And Push Buttons 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Changing Temperature Units (5F or 5C) Or Changing Temperature Read And Alter Setting 12
SECTION 5 – OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Safety Equipment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Sequence Of Induction Heating Process 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – ELECTRICAL DIAGRAMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-193 253
OM-193 253 Page 1
SECTION 1 SAFETY PRECAUTIONS READ BEFORE
USING
1-1. Symbol Usage
safety_ihom 5/98
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Induction Heating Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine
internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Enclose any connecting bus bars and coolant fittings to prevent
unintentional contact.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
D Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
D Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
D Properly install and ground this equipment according to its Owners
Manual and national, state, and local codes.
D Always verify the supply ground check and be sure that input pow-
er cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding
conductor first double-check connections.
D Frequently inspect input power cord for damage or bare wiring re-
place cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D Do not touch power circuit if you are in contact with the work,
ground, or another power circuit from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
INDUCTION HEATING can cause burns.
D Hot parts and equipment can injure.
D Do not touch or handle induction head/coil
during operation.
D Do not touch hot parts bare-handed.
D Allow cooling period before handling parts or equipment.
D Keep metal jewelry and other metal personal items away from
head/coil during operation.
FIRE OR EXPLOSION hazard.
D Do not overheat parts and adhesive.
D Watch for fire; keep extinguisher nearby.
D Keep flammables away from work area.
D Do not locate unit on, over, or near combustible surfaces.
D Do not install unit near flammables.
D Do not operate unit in explosive atmosphere.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust to remove fumes
and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson
nearby. Fumes and gases from heating can displace air and lower
the oxygen level causing injury or death. Be sure the breathing air is
safe.
D Do not heat in locations near degreasing, cleaning, or spraying op-
erations. The heat can react with vapors to form highly toxic and
irritating gases.
D Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if overheated.
See coating MSDS for temperature information.
OM-193 253 Page 2
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING UNIT can cause injury.
D Use handle and have person of adequate
physical strength lift unit.
D Move unit with hand cart or similar device.
D For units without a handle, use equipment of
adequate capacity to lift unit.
D When using lift forks to move unit, be sure forks are long enough
to extend beyond opposite side of unit.
FLYING METAL OR ADHESIVE can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near induction heating operations.
OVERUSE can cause OVERHEATING
D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified person familiar with electronic equipment per-
form this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut.
1-4. Principal Safety Standards
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 178 Rexdale Boulevard,Rex-
dale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
1-5. EMF Information
Considerations About Induction Heating And The Effects Of Low Fre-
quency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields Background Paper,
OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): . . . there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can
interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientif-
ic understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow
us to draw definite conclusions about questions of possible risk or to of-
fer clear science-based advice on strategies to minimize or avoid
potential risks.
To reduce magnetic fields in the workplace, use the following proce-
dures:
1. Arrange output cable to one side and away from the operator.
2. Do not coil or drape output cable around the body.
3. Keep power source and cable as far away from the operator as
practical.
About Pacemakers:
The above procedures are also recommended for pacemaker wearers.
Consult your doctor for complete information.
OM-193 253 Page 3
SECTION 1 MESURES DE SECURITE POUR LE
CHAUFFAGE PAR INDUCTION
safetyihom_fre 5/98
PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE
MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS DUN STIMULATEUR CARDIAQUE DOIVENT
PREALABLEMENT CONSULTER LEUR MEDECIN.
Pendant les opérations de chauffage, comme dans la plupart des activités, lopérateur sexpose à certains dangers.
Le chauffage nest pas dangereux à condition de prendre certaines mesures. Les consignes de sécurité indiquées
ci-après ne sont quun résumé des informations plus détaillées se trouvant dans les normes de sécurité énumérées
à la page suivante. Lire et respecter toutes les normes de sécurité.
LES OPERATIONS DINSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT
ETRE CONFIEES QUA DU PERSONNEL QUALIFIE.
LE CHAUFFAGE PAR INDUCTION peut être dangereux.
AVERTISSEMENT
Danger de mort PAR ELECTROCUTION.
Le contact de composants électriques peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de puissance et les connexions de
sortie sont sous tension lorsquon active la sortie. Le
circuit dalimentation et les circuits internes de la
machine sont également sous tension lorsque
lalimentation est sur marche. Des équipements
installés ou reliés à la borne de terre de manière
incorrecte sont dangereux.
1. Ne pas toucher des composants électriques sous tension.
2. Envelopper les connexions et raccords de refroidissement pour
éviter tout contact accidentel.
3. Porter des gants disolation secs, sans trous, et une protection
corporelle.
4. Isolez-vous de la pièce et du sol avec des tapis ou des
couvertures disolation suffisamment grands pour prévenir tout
contact physique avec la pièce ou la terre.
5. Déconnecter lalimentation avant dinstaller lappareil ou den
effectuer lentretien. Verrouiller ou étiqueter la sortie
dalimentation selon la norme OSHA 29 CFR 1910.147
(se reporter aux Principales normes de sécurité).
6. Utiliser seulement des tuyaux non conducteurs avec une
longueur minimale de 460 mm pour assurer lisolement.
7. Installer et mettre cet équipement correctement à la terre
conformément au manuel utilisateur et aux codes nationaux,
gouvernementaux et locaux.
8. Vérifier souvent la terre de lalimentation contrôler et sassurer
que le conducteur de terre du câble dalimentation est
correctement relié à la borne de terre dans le boîtier de
déconnexion ou que le connecteur est branché à une sortie de
boîtier correctement mise à la terre.
9. En réalisant des connexions dentrée brancher dabord le
conducteur de terre approprié contrôler deux fois les
connexions.
10. Vérifier souvent le bon état du câble dalimentation ou lisolation
des fils remplacer le câble immédiatement sil est endommagé
des fils dénudés peuvent provoquer des accidents mortels.
11. Arrêter tous les équipements lorsquils ne sont pas utilisés.
12. Ne pas utiliser des câbles usés, endommagés, sous
dimensionnés ou mal épissés.
13. Ne pas porter les câbles autour de votre corps.
14. Ne pas toucher le circuit électrique si vous êtes en contact avec la
pièce, la terre ou le circuit électrique dune autre machine.
15. Utiliser seulement des équipements bien entretenus. Réparer ou
remplacer immédiatement des composants endommagés.
Effectuer des travaux dentretien sur lappareil selon le manuel.
16. Porter un harnais de sécurité pour effectuer des travaux
au-dessus du sol.
17. Maintenir solidement en place tous les panneaux et couvercles.
LE CHAUFFAGE PAR INDUCTION peut
provoquer des blessures ou des
brûlures au contact de PIECES
CHAUDES OU DE LEQUIPEMENT.
1. Ne pas toucher ou manipuler la tête/lenroulement à induction
pendant le fonctionnement.
2. Tenir les bijoux et autres objets personnels en métal éloignés de
la tête/de lenroulement pendant le fonctionnement.
3. Laisser refroidir les composants ou équipements avant de les
manipuler.
LE CHAUFFAGE PAR INDUCTION peut
provoquer un incendie.
1. Ne pas surchauffer les composants ni les
adhésifs.
2. Attention aux risques dincendie: tenir un
extincteur à proximité.
3. Stocker des produits inflammables hors de la
zone de travail.
La mise en place de lappareil sur, au-dessus ou à
proximité de surfaces inflammables peut être source
dINCENDIES OU dEXPLOSION.
1. Ne pas placer lappareil sur, au-dessus ou à proximité de
surfaces infllammables.
2. Ne pas installer lappareil à proximité de produits inflammables
3. Ne pas faire fonctionner lappareil en atmosphère explosive.
OM-193 253 Page 4
DES FUMEES ET DES GAZ peuvent
être dangereux pour votre santé.
Le chauffage à induction génère des fumées et des
gaz. Leur inhalation peut être dangereuse pour votre
santé.
1. Eloigner la tête des fumées. Ne pas respirer les fumées.
2. A linterieur, ventiler la zone et/ou utiliser un extracteur pour
l’évacuation des fumées et des gaz.
3. Si la ventilation est insuffisante, utiliser un respirateur à
alimentation dair homologué.
4. Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les adhésifs, les métaux, les
consommables, les revêtements, les nettoyants et les
dégraisseurs.
5. Travailler dans un espace fermé seulement sil est bien ventilé ou
en portant un respirateur. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz
provenant du chauffage peuvent déplacer lair, abaisser le niveau
doxygène, et provoquer des lésions ou des accidents mortels.
Sassurer que lair ambiant ne présente aucun danger.
6. Ne pas chauffer dans des endroits se trouvant à proximité
dopérations de dégraissage, de nettoyage ou de pulvérisation. La
chaleur peut réagir en présence de vapeurs et former des gaz
hautement toxiques et irritants.
7. Ne pas chauffer des métaux munis dun revêtement tels que lacier
galvanisé, plaqué au plomb ou au cadmium, à moins que le
revêtement ne soit enlevé de la zone chauffée, que la zone soit
bien ventilée et, si nécessaire, en portant un respirateur. Les
revêtements et tous les métaux contenant ces éléments peuvent
dégager des fumées toxiques sils sont chauffés.
1-1. Dangers supplémentaires de mise en route, de fonctionnement et dentretien
LA CHUTE DE MATERIEL peut provoquer
des blessures personnelles graves et en-
dommager les équipements.
1. Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever
lappareil.
2. Déplacer lappareil à laide dun charriot ou dun
engin similaire.
3. Pour les appareils sans poignée utiliser un équipe-
ment dune capacité appropriée pour soulever
lappareil.
4. En utilisant des fourches de levage pour déplacer
lunité, sassurer que les fourches sont suffisamment
longues pour dépasser du côté opposé de lappareil.
LA PROJECTION DE PIECES DE METAL ou
DE COLLE peut provoquer des blessures
aux yeux.
1. Porter des lunettes de protection avec des protec-
tions latérales.
DES ORGANES MOBILES peuvent
provoquer des blessures.
1. Sabstenir de toucher des organes mobiles tels que
des ventilateurs.
2. Maintenir fermés et fixement en place les portes, pan-
neaux, recouvrements et dispositifs de protection.
DES CHAMPS MAGNETIQUES CREES PAR
DES COURANTS ELEVES peuvent affecter le
fonctionnement du stimulateur cardiaque.
1. Porteurs de stimulateur cardiaque, restez à distance.
2. Les porteurs dun stimulateur cardiaque doivent da-
bord consulter leur médecin avant de sapprocher
des opérations de chauffage à induction.
UNE UTILISATION INTENSIVE peut provo-
quer un SURCHAUFFEMENT DU MATERIEL.
1. Prévoir une période de refroidissement
2. Réduire le courant de sortie ou le facteur de marche
avant de recommencer le chauffage.
3. Respecter le facteur de marche nominal.
LELECTRICITE STATIQUE peut endomma-
ger les composants des tableaux électri-
ques.
1. Etablir la connexion avec la barrette de terre avant
de manipuler des cartes ou des pièces.
2. Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
Il subsiste DU COURANT CONTINU IMPOR-
TANT après la mise hors tension de lalimen-
tation électrique.
1. Avant de toucher des organes internes, arrêter la
source électrique, débrancher lalimentation, et dé-
charger les condensateurs dalimentation conformé-
ment aux instructions indiquées dans la partie main-
tenance.
LE RAYONNEMENT HAUTE FREQUENCE
peut provoquer des interférences avec les
équipements de radio-navigation et de com-
munication, les services de sécurité et les or-
dinateurs.
Demander seulement à des personnes qualifiées
familiarisées avec des équipements électroniques
de faire fonctionner linstallation.
Lutilisateur est tenu de faire corriger rapidement par
un électricien qualifié les interférences résultant de
linstallation.
Si le FCC signale des interférences, arrêter immé-
diatement lappareil.
Effectuer régulièrement le contrôle et lentretien de
linstallation.
Maintenir soigneusement fermés les portes et les
panneaux des sources de haute fréquence.
OM-193 253 Page 5
1-2. Informations concernant les champs électro-magnétiques (Information EMF)
Considérations relatives au chauffage à induction et aux effets des
champs électriques et magnétiques basse fréquence.
Le texte suivant est extrait des conclusions générales Département
du Congrès U.S., Office of Technology Assessment, Effets
biologiques des champs magnétiques et électriques basse
fréquence Background Paper, OTA-BP-E-53 (Washington, DC:
U.S. Government Printing Office, May 1989): . . . on dispose
maintenant dimportantes découvertes scientifiques reposant sur
des expériences effectuées dans le domaine cellulaire et des études
réalisées sur des animaux et des personnes qui démontrent
clairement que des champs magnétiques basse fréquence peuvent
avoir une interaction et produire des changements dans les
systèmes biologiques. Alors que la plus grande partie de cet ouvrage
est dune très grande qualité, les résultats sont complexes. La
compréhension scientifique courante ne nous permet pas encore
dinterpréter la preuve fournie dans un seul ouvrage cohérent. Il est
encore plus frustrant de ne pas pouvoir tirer des conclusions
définitives en ce qui concerne les problèmes de risque possible ou de
proposer des recommandations scientifiques claires pour des
stratégies à suivre en vue de minimiser ou de prévenir des risques
potentiels.
Pour réduire les champs magnétiques sur le poste de travail,
appliquer les procédures suivantes :
4. Disposer le câble de sortie dun côté à distance de lopérateur
5. Ne pas enrouler ou draper le câble électrique autour du corps.
6. Placer la source de courant et le câble le plus loin possible de
lopérateur.
En ce qui concerne les stimulateurs cardiaques
Les procédures ci-dessus concernent également les porteurs de
stimulateur cardiaque. Consulter votre médecin pour un complément
dinformation.
PRINCIPALES NORMES DE SÉCURITÉ
Normes de sécurité et de santé, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Code électrique national, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Code électrique du Canada, partie 1, CSA Standard C22.1, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard,Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
OM-193 253 Page 6
SECTION 2 INTRODUCTION
The Induction Heating Temperature Controller (IH/TC) is designed to be used with Induction Heating Power Supplies
(IHPS), which includes both the IHPS II and Intellifire power source. The controller design allows operating any IHPS
either in simple on/off fashion or more accurate Proportional, Integral, Derivative (PID) mode.
The IH/TC comes preset from the factory to operate in most preheat applications. However, there will be some ap-
plications where preset defaults will not be adequate; therefore, these instructions will guide the operator in the proper
use of the controller and, when needed, programming the controller for specific applications.
Basic Operation
The controller comes from the factory already setup for use as is and should meet most preheat applications.
Connect the controller as shown in Section 3 and use the up/down buttons (see Section 4-1) to select a target. To
prevent this target from being changed by anyone except the programmer, it can be made a read only value to the
operator (see Section 4-2).
If the remote/panel switch located on the power source front panel is in the remote position, the controller will function
in a PID mode. In this case, the controller will attempt to bring the workpiece to the exact temperature (with minimal
overshoot) as fast as possible.
If the remote/panel switch located on the power source front panel is in the panel position, the controller will simply
turn on the power source until the workpiece is at the set temperature.
When operating in the simple on/off mode, the power source will deliver whatever
power is set on its front panel control dial. This mode may cause significant
temperature overshoot, but it is the fastest way to reach a given target
temperature if the amount of overshoot can be tolerated.
NOTE
When workpiece temperature falls 2 degrees below the target, the controller turns the power source on and the cycle
begins again.
OM-193 253 Page 7
. After completing the system hookup, determine the desired heating process:
Heat as fast as possible and remove blanket when reaching workpiece target temperature (temperature of
workpiece will have some overshoot with this process.
or
Target and maintain workpiece target temperature.
Heat And Remove Blanket Maintain Target Temperature
1. Start with all switches in Off position for units in
the system.
1. Start with all switches in Off position for units in
the system.
2. Place power source Panel/Remote switch in
Panel position.
2. Place power source Panel/Remote switch in the
Remote* position.
3. Set power source Power Adjust knob to desired
output setting.
3. Set power source Power Adjust knob to max
output setting.
4. Place power source Power switch in the On position.
5. Is the system equipped with a remote On/Off switch?
Yes Set IH/TC Panel/Remote switch to Remote position
No Set IH/TC Panel/Remote switch to Panel position
6. Make adjustment for desired temperature target on controller using up/down buttons.
7. Install induction blanket onto workpiece. Be sure that blanket is in full contact with workpiece surface for
even heating.
8. Insert temperature probe under blanket so that flat portion of probe tip is in full contact with workpiece
surface.
9. To start heating cycle, turn controller output switch to On.
If system is equipped with a remote On/Off switch, place this switch in the On position.
Turning off either the controller output switch or remote On/Off switch will disable power source output.
10. Controller will turn off power source output when
workpiece reaches target temperature. Some
overshoot will occur.
10. Controller will reduce power source output as
workpiece approaches target temperature.
Controller maintains workpiece target temperature
by regulating power source output.
11. Turning off either the controller output switch or remote On/Off switch disables the power source output.
Caution: Do Not touch hot parts bare-handed.Remove blanket and temperature probe from workpiece.
. *Depending on the vintage of the power source, when the Panel/Remote switch is set to Remote, the controller
will have either Master/Slave control (the control can only go as high as the Power Adjust knob setting) or full
control (100% of power source output).
. To determine if master/slave control is present:
Energize power source output and turn output knob up and down scale. Listen for an audible frequency change
in the power source.
If an Induction Heating Pendent Control (IH/PC) is available, the Power (KW) reading will change with output
knob setting.
If there is not audible frequency change and the power reading does not change, master/slave control is not
present.
OM-193 253 Page 8
SECTION 3 INSTALLATION
3-1. Specifications
Specification Description
Overall Dimensions Height: 4 in (102 mm); Width: 6-1/2 in (165 mm); Depth: 9 in (229 mm)
Weight Net: 4 lb (1.8 kg)
Type Of Input Power 24 Volts DC
Interconnecting Cord With Plugs 30 in (762 mm)
Extension Cord (Optional) 25 ft (7.6 m)
Memory Capacity One Program Up To 8 Segments
Control Capacity Single Power Source Control
Operating Temperature Range 14° To 131° F (10° To 55° C)
Storage Temperature Range 40° To 167° F (40° To 75° C)
802 615 / 802 613
3-2. IH/TC Installation
1
1
2
3
Tools Needed:
3/8, 7/16 in
Y Turn Off and disconnect
input power.
1 Temperature Controller
2 Mounting Bracket
3 Screw (2)
4 Shoulder Nut (2)
Install and secure temperature con-
troller to mounting bracket using
supplied screws and nuts.
5 Power Source Case
6 Case Sheet Metal Screw (4)
Remove case sheet metal screws
from both left and right side of unit.
Install mounting bracket to power
source, and secure by reinstalling
sheet metal screws.
3
4
5
6
OM-193 253 Page 9
3-3. Connecting To Power Source
Turn Off power source.
1 IH/TC
2 Interconnecting Cord
3 14-Socket Plug
4 14-Pin Plug
Obtain cord with 14-socket plug on
one end and 14-pin plug on other
end.
5 Keyway
6 Remote 14 Receptacle RC1
(See Section 3-4)
To connect cord to a receptacle,
align keyway, insert plug, and
tighten threaded collar.
To connect remaining end of cord to
power source, align keyway, insert
plug, and tighten threaded collar.
2
JA
I
K
B
H
N
L
C
G
M
D
F
E
5
6
sb7.1* 3/93 - Ref. S-0004-A / S-0750 / Ref. 802 616-A / Ref. 801 049 / 801 825-B
1
3
4
3-4. Input 14 Pin Information For Receptacle RC1
REMOTE 14
Pin Pin Information
A +24 volts dc from power source.
Remote Contactor
B Contact closure to A completes power source +24 volts dc contactor control circuit.
D Control circuit common.
Remote Output Control
E 0 to +10 volts dc signal for power source output control.
Power Source Fault
F, J Absence of contact closure from power source indicates power source output failure.
I Actual frequency input signal.
L Average power input signal.
Remote Metering*
M Voltage input signal RMS.
N Current input signal RMS.
Chassis Common
K Power source chassis common.
*See power source Owners Manual for scaling information.
OM-193 253 Page 10
3-5. Remote Start/Stop Switch Or IH/PC Connections
A remote maintained contact
switch or IH/PC can be connected
to the temperature controller to start
or stop the heating program.
. The IH/PC will display
operating parameters.
Turn Off power source.
1 Interconnecting Cord
(Customer Supplied)
2 14-Pin Plug
Obtain cord and install supplied
plug on one end.
3 Keyway
4 Remote Start/Stop
Receptacle RC2 (See Section
3-6)
To connect cord to receptacle, align
keyway, insert plug, and tighten
threaded collar.
To connect remaining end of cord,
make connections to maintained
contact switch.
1
3
4
2
Ref. S-0446-A / Ref. 802 616-A / S-0628-A
JA
I
K
B
H
N
LC
G
M
D
F
E
3-6. Remote Start/Stop Socket Information For Receptacle RC2
START/STOP
Socket Socket Information
A +24 volts dc.
Remote Start/Stop
B Maintained contact closure to socket A starts the heating cycle. Opening the contact
closure or turning off the output switch on the pendant stops the heating cycle.
D Control circuit common.
Remote Output Control
E 0 to +10 volts dc signal for power source output control.
Power Source Fault
F, J Absence of contact closure from power source indicates power source output failure.
I Actual frequency output signal.
L Average power output signal.
Remote Metering
M Voltage output signal RMS.
N Current output signal RMS.
K Power source chassis common.
OM-193 253 Page 11
3-7. Connecting External Device
This control must be connected to an
external device, such as a thermocouple or
RTD.
To connect external device, proceed as
follows:
Turn Off power source.
1 Temperature Controller
2 Thermocouple
3 Thermocouple Extension Cord
Obtain cord and install supplied plug on one
end.
4 Thermocouple Receptacle RC3
To connect cord to receptacle, align pins
and insert plug.
To connect remaining end of cord, make
connections to external temperature
sensor.
2
3
802 616-A
1
4
SECTION 4 PROGRAMMING
4-1. Digital Display And Push Buttons
Y Keep all panels, doors, and
covers closed and secure
during programming.
1 Digital Display
2 Auto/Man Select Button*
3 Run/Hold Select Button*
4 Page Forward Button{
5 Scroll Button{
6 Down Button{
7 Up Button{
8 Read Temperature
9 Set Temperature
*Disabled from factory.
{These buttons are used to
navigate through menu systems.
1
2
4
3
AUTO
MAN
RUN
HOLD
B Y
567
88
350
OP1
SP2
8
9
Home
Display
OM-193 253 Page 12
4-2. Changing Temperature Units (5F or 5C) Or Changing Temperature Read And Alter
Setting
Use the following instructions if changes are required to Temperature units or
target read/alter.
NOTE
Press Page to
AccS
LiSt
codE
0
Y
codE
1
Wait
2 sec.
codE
PASS
Goto
OPEr
Y to
to
75
ALtr
75
rEAd
Accs
LiSt
CodE
PASS
CodE
0
75
350
Goto
ConF
ConF
0
Y
ConF
2
Wait
2 sec.
toB
B
to
ConF
PASS
PU
ConF
Y
unit
%F
Exit
no
Exit
YES
to
to
to change the
operating Temperature
units to F, C or k
Y B
Wait 2 seconds
Controller resets
Goto
Edit
toB
Goto
Ful
toB
75
rEAd
Y to
75
ALtr
to
Set to Read for reading only
access on the home display
Set to Alter to allow changes
to the target temperature on
the home display
OM-193 253 Page 13
SECTION 5 OPERATION
5-1. Controls
Y Keep all panels, doors, and
covers closed and secure
during programming and op-
eration.
1 Temperature Controller
2 Output On/Off Switch And
Pilot Light
3 Heat On Pilot Light
4 Output Control Remote/Panel
Switch
5 Digital Display
6 Down Button*
7 Up Button*
*These buttons are used to adjust
target temperature.
5
AUTO
MAN
RUN
HOLD
B Y
67
88
350
OP1
SP2
1234
5
Ref. 802 614
5-2. Safety Equipment
Wear the following during
operation:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
sb3.1* 1/94
12
5-3. Sequence Of Induction Heating Process
Install & Connect
Induction Heating
Equipment
Put On
Personal Safety
Equipment
Turn On
Power
Source
Enter
Target
Temperature
Turn On IHTC And
Remote On/Off,
If Required
Start
Heating
Process
OM-193 253 Page 14
SECTION 6 MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
Turn Off all power before maintaining.
3 Months
OR
Blow Out
Or
Vacuum
Inside
Replace
Unreadable
Labels
6 Months
Replace
Cracked
Parts
6-2. Troubleshooting
Trouble Remedy
No heat output. Secure interconnecting cord plug in pendant receptacle (see Section 3-3).
Secure interconnecting cord plug in power source receptacle (see Section 3-3).
Check remote start switch and, if applicable, external device connections (see Sections 3-5 and 3-7).
Replace building line fuse or reset circuit breaker.
Display flashes 5.br
1dHi
Open thermocouple. Reconnect or replace thermocouple.
Conf 0 appears on the display. Press the up arrow to change the 0 to 2. Press scroll to enter the menu. Press page to Exit no and change
it to Exit YES, and the controller will reset automatically.
Power source contactor turns On
and Off at 5° over target
temperature.
Change Panel/Remote switch on power source to Remote position.
If display flashes no.io. Remove 2416 control from its housing by pressing locking tabs outward slightly on sides of control and pulling
control forward. Look for addon PC card in back of controller, and check that white connector is fully inserted
into 2416 control. Reinstall 2416 control into housing being careful not to damage locking tabs on housing.
If display flashes no.io again, or if
0-10 V output card fails.
Remove 2416 control from its housing by pressing locking tabs outward slightly on sides of control and pulling
control forward. Look for addon PC card in back of controller, and remove PC card. Reinstall 2416 control
into housing being careful not to damage locking tabs on housing. Disable output card function as follows:
Goto ConF, IA ConF.
Change id dc.OP to id nonE.
Scroll to Exit no and change it to Exit YES, and the controller will reset automatically.
Set power source panel / remote switch to panel position and set desired maximum output. The control will
operate in an on / off mode (at target temp + over temp alarm value).
The over temp alarm value is set in Goto Ful, AL LiSt, IdHi.
Obtain a replacement 0-10 V isolated card.
OM-193 253 Page 15
SECTION 7 ELECTRICAL DIAGRAMS
197 065-A
Figure 6-1. Circuit Diagram For IH/TC
198 065-A
Figure 6-2. Wiring Diagram For IH/TC
OM-175 211 Page 16
SECTION 8 PARTS LIST
Ref.802 612
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 7-1. Complete Assembly
Description
Part
No.
Dia.
Mkgs.
Figure 7-1. Complete Assembly
Quantity
1 197 061 TEMPERATURE CONTROLLER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 199 050 MOUNT, NPRN temperature control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 143 976 RECEPTACLE W/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 136 691 CONNECTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 198 885 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 197 048 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 170 391 CONNECTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 198 893 RECEPTACLE, thermocouple type K 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 NAMEPLATE, rear (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 197 047 CASE SECTION, front/bottom/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 198 760 CABLE, extension 25ft TC type K 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 194 673 TEMPERATURE SENSOR, type K 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 152 492 RECEPTACLE W/PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 197 050 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 NAMEPLATE, front (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 159 039 SWITCH, rocker SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 120 376 SWITCH, rocker SPDT 4A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 197 062 LIGHT, ind wht lens 28V snap mt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
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Miller I Owner's manual

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