Beruflich Dokumente
Kultur Dokumente
January 2005
Processes
Induction Heating
Description
IHPS II 5 KW
www.MillerWelds.com
Mil_Thank 7/03
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de lappareil. . . . . . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Connecting Head/Coil To Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Remote 14 Receptacle RC14 Information And Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote 14 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Power Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Power Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Ground Fault Test Switch And Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Sequence Of Induction Heating Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Automatic Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Safety Interlock Switch And Measuring Tuning Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Tuning Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
3
3
4
4
5
5
5
7
8
8
8
9
9
9
10
10
11
12
12
13
13
13
13
14
14
14
14
15
15
16
16
16
17
18
18
19
19
20
22
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground check and be sure that input
power 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
replace 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 weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D
D
D
D
D
D
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (phone: 6177703000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:
6177703000,website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Officesphone for Region 5, Chicago, is
3123532220,website: www.osha.gov).
Ce groupe de symboles signifie Mise en garde. Faire preuve de vigilance. Il y a des dangers lis aux CHOCS LECTRIQUES, aux
PICES EN MOUVEMENT et aux PICES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.
Ne pas se servir dune source de courant alternatif dans les zones humides, les endroits confins ou l o on risque de tomber.
Ne se servir dune source de courant alternatif QUE si le procd de soudage lexige.
Si lutilisation dune source de courant alternatif savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.
D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Couper/tiqueter
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de scurit).
D Installer et mettre la terre correctement lappareil conformment
son manuel dutilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la
borne de terre du sectionneur ou que la fiche du cordon est raccorde
une prise correctement mise la terre.
D Pour excuter les branchements dentre, fixer dabord le conducteur
de mise la terre adquat et contrevrifier les connexions.
D Vrifier frquemment le cordon dalimentation et sassurer quil nest
ni endommag ni dnud ; le remplacer immdiatement sil est endommag tout cble dnud peut causer une lectrocution.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou
mal pisss.
D Ne pas senrouler les cbles autour du corps.
D Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct.
D Ne pas toucher llectrode quand on est en contact avec la pice, la
terre ou une lectrode dune autre machine.
Les BOUTEILLES
peuvent exploser.
endommages
D Ne pas placer lappareil sur une surface inflammable, ni audessus ou proximit delle.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (tlphone : (305) 4439353, site Web : www.aws.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de lU.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312)
3532220, site Web : www.osha.gov).
Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes :
1. Garder les cbles ensemble en les torsadant ou en les fixant avec du
ruban adhsif.
2. Mettre tous les cbles du ct oppos loprateur.
3. Ne pas senrouler les cbles autour du corps.
4. Garder le poste de soudage et les cbles le plus loin possible de soi.
5. Placer la pince de masse le plus prs possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.
SECTION 3 SPECIFICATIONS
Type of
Input Power
Three-Phase,
230 Or 460
Volts AC,
50/60 Hz
Output
Frequency
Rated
Output
10 To 50 kHz
5 kW At 100%
Duty Cycle;
Max 200 A
(RMS), 350 V
(RMS)
Required
Reflective
Inductance
5 to 30 h
Input
Amperes At
Rated Output
KVA/KW
Used At
Rated Output
22 A At 230 V
*0.6 A;
11 A At 460 V
*0.3 A
8.5 kVA/6.3 kW
*0.15 kVA/0.146
kW
Overall
Dimensions
Length: 19-1/2
in (495 mm)
Width: 11-1/2 in
(292 mm)
Height: 11-3/4 in
(298 mm)
Weight
Net: 65 lb
(29.5 kg)
Ship: 70 lb
(31.8 kg)
*While idling
SECTION 4 INSTALLATION
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,
computers, and communications equipment.
Have only qualified person familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut.
Rear Panel
3
2
Socket Information:
A, C
B, D
1
2
3
4
3
4
B
Plug
Threaded Collar
Keyway
Remote 14 Receptacle RC14
(See Section 4-3)
H
C L N
D M
G
E F
4
A
B
H
C L N
D M
G
E F
4
Remote
Output
Control
Power
Source
Fault
Remote
Metering
Socket Information
Not used.
F,J
Absence of internal contact closure between F and J signals power source failure to remote control device.
Voltage
g output
p signal
g
RMS (1
( volt/50
/ volts).
)
Current output
p signal
g
RMS (1
( volt/50 amperes).
p
)
Chassis common.
Reinstall wrapper or go on to
Section 4-5.
230
460
230
230
460 230
S-170 603-A
Tools Needed:
5/16 in
2
3
Input Conductors
Grounding Conductor
5
2
3
Overcurrent Protection
Tools Needed:
5/16 in
Ref. 802 664
230
460
22
11
30
15
10
14
200
(61)
318
(97)
10
14
SECTION 5 OPERATION
5-1. Controls
1
2
3
4
2
3
4
Ref. 802 662
Insulating Gloves
Safety Glasses With Side
Shields
sb3.1* 10/91
Power Switch
Pilot Light
PRESS
TO
TEST
1
FAULT
Put On
Personal Safety
Equipment
Turn On
Coolant Supply,
If Required
Set
Controls
Position Work
Near
Head/Coil
Turn On
Power
Switch
Wait
10 Seconds
Unit Ready
To Heat
3 Months
Clean And
Tighten Output
Connections
Repair Or Replace
Cracked Output
Cables
6 Months
Replace
Damaged Or
Unreadable
Labels
Blow Out Or
Vacuum Inside
Tools Needed:
5/16 in
Power Source
Receptacle
Plug
To connect plug, align key with keyway, insert end into receptacle, and
rotate plug until tight.
4
5
6
Handle
Magnet
Workpiece
3
Significant AC voltage can remain on
capacitors after unit is Off. Always
check capacitors as shown to be sure
they have discharged before working
on unit.
Tools Needed:
5/16 in
and
Remove wrapper.
1
2
3
Input Capacitor C1
Input Capacitor C2
Voltmeter
Tools Needed:
5/16 in
800 998-C
6-8. Troubleshooting
Y Disconnect power before troubleshooting
Trouble
Remedy
No heat output.
Replace building line fuses, reset circuit breaker, or replace unit fuse(s) F1, F2, and/or F3
(see Section 4-5).
Secure head/coil plug in power source receptacle (see Section 4-1).
Check and replace Power switch if necessary.
Connect power source to proper input voltage or check for low line voltage
(see Sections 4-4 and 4-5).
No heat output; fan motor continues to Tuning capacitor cover safety interlock switch open. Close tuning capacitor cover
run.
(see Section 6-6).
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit
has cooled (see Section 6-3).
Low heat output.
No +24 volts dc output at 14-socket Check fuse F4, and replace if necessary (see Section 6-2).
receptacle.
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
High
Low
High
Add capacitance
High
Low
Mid-Range
Low
High
Low
Lower capacitance
Low
High
High
Low
High
Mid-Range
*High voltage > 300 V rms; Low voltage < 200 V rms; Operating current range: 0 to 200 A rms
218 030-A
60
10
59
65
71
70
69
68
11
66
61
12
58
63
62
64
16
13 15
14
57
17
18
54
19
20
55
21
22
56
23
50
51
25
52
53
24
28
27
49
26
48
29
30
47
31
72
46
33
32
36
37
34
35
45
43
42
41
40
39
38
44
802 666-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
4
1
1
1
3
1
1
1
4
1
1ft
8
2
4
2
2
1
1
1
3
3
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
4
4
2
3
3
1
1
1
1
1
1
1
1
5
2
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
4
1
1
1
1
4
1
1
1
1
Notes
Notes
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
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Remote Controls
Accessory Kits
Spoolmate Spoolguns
Canvas Covers
2.
3.
1.
*
*
2.
*
*
*
*
3.
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
4.
6 Months Batteries
5.
90 Days Parts
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
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