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OM-184 227K
2006 −05
Processes
Induction Heating
Description
Induction Heating Power Source
Intellifire 250
File: Induction Heating
Visit our website at
www.MillerWelds.com
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From Miller to You 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 bu
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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, Opera
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage safety_ihom 5/05 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Means “Note”; not safety related. Consult symbols
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FIRE OR EXPLOSION hazard. INDUCTION HEATING can cause burns. Do not overheat parts and adhesive. Hot parts and equipment can injure. Watch for fire; keep extinguisher nearby. Do not touch or handle induction head/coil during operation. Keep flammables away from work area. Do not touch hot parts bare-handed. Do not locate unit on, over, or near combustible surfaces. Allow cooling period before handling parts or equipment. Do not install unit near flammables. Keep metal jewelry
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1-6. EMF Information Considerations About Induction Heating And The Effects Of Low Fre- us to draw definite conclusions about questions of possible risk or to of- quency Electric And Magnetic Fields fer clear science-based advice on strategies to minimize or avoid potential risks.” The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of To reduce magnetic fields in the workplace, use the following proce- Power
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SECTION 2 − MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION ihom_fre 8/03 LE CHAUFFAGE PAR INDUCTION peut être dangereux. AVERTISSEMENT PRENDRE LES MESURES NECESSAIRES POUR EVITER LES RISQUES DE BLESSURES GRAVES, VOIRE MORTELLES. TENIR LES ENFANTS A DISTANCE. LES PORTEURS D’UN STIMULATEUR CARDIAQUE DOIVENT PREALABLEMENT CONSULTER LEUR MEDECIN. Pendant les opérations de chauffage, comme dans la plupart des activités, l’opérateur s’expose à certains dangers. Le chauffage n’est pas dangereux à
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5. Travailler dans un espace fermé seulement s’il est bien ventilé ou DES FUMEES ET DES GAZ peuvent en portant un respirateur. Demander toujours à un surveillant être dangereux pour votre santé. dûment formé de se tenir à proximité. Des fumées et des gaz Le chauffage à induction génère des fumées et des provenant du chauffage peuvent déplacer l’air, abaisser le niveau gaz. Leur inhalation peut être dangereuse pour votre d’oxygène, et provoquer des lésions ou des accidents mortels. santé. S’assur
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2-2. Informations concernant les champs électro-magnétiques (Information EMF) Considérations relatives au chauffage à induction et aux effets des proposer des recommandations scientifiques claires pour des champs électriques et magnétiques basse fréquence. stratégies à suivre en vue de minimiser ou de prévenir des risques potentiels.” Le texte suivant est extrait des conclusions générales Département du Congrès U.S., Office of Technology Assessment, Effets Pour réduire les champs magnétiques sur
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SECTION 3 − INSTALLATION 3-1. Specifications Amperes Input at Required Rated Load Output 50 Output Reflective Rated Output or 60 Hz, Three-Phase Overall Dimensions Weight Frequency Frequency Inductance Inductance 460 V KVA KW Length: 31 in 25 kW At (787 mm) 100% Duty 39 Width: 16 in 165 lb 10 To 50 kHz Cycle − Max 2.5 To 50 μh 30.8 27.19 0.29* (406 mm) (75 kg) 750 A (RMS), Height: 27 in 700 V (RMS) (686 mm) *While idling WARNING HIGH-FREQUENCY RADIATION can interfere with radio navigation, safet
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3-3. Remote 14 Receptacle RC14 Information and Connections 1 Front Panel 2 Plug 1 3 Threaded Collar 4 Keyway 5 Remote 14 Receptacle RC14 (See Section 3-4) To connect to receptacle, align key- way, insert plug, and tighten threaded collar. 4 AJ 5 K I B L NH C M D G F E 3 2 sb7.1* 3/93 - Ref. S-0004-A / Ref. S-0750 / Ref. ST-801 826-C 3-4. Remote 14 Socket Information Socket Socket Information +24 volts dc. A Remote Contactor Remote Contactor Contact closure to A completes 24 volts dc contactor co
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3-5. Connecting 3-Phase Input Power For Models With Customer Supplied Cord Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. 3 Make input power connections to the welding power source first. = GND/PE Earth Ground Always connect green or green/ 9 yellow conductor to supply grounding terminal first, and never to a line terminal. 8 See rating
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3-6. Electrical Service Guide 60 Hz Three Phase Input Voltage 460 Input Amperes At Rated Output 39 1 Max Recommended Standard Fuse Rating In Amperes 2 Time-Delay 45 3 Normal Operating 60 4 Min Input Conductor Size In AWG 8 287 Max Recommended Input Conductor Length In Feet (Meters) (87) 4 Min Grounding Conductor Size In AWG 10 Reference: 2005 National Electrical Code (NEC) (including article 630) 1 Consult factory for circuit breaker applications. 2 “Time-Delay” fuses are UL class “RK5” . 3 “No
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SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Clean and tighten Repair or replace output connections. cracked cables and cords. 6 Months Replace damaged or Blow out or vacuum unreadable labels. inside. 5-2. Overheating Thermostats TP1, TP2, and TP3 protect the unit from damage due to overheating. If one or more of the heat sinks get too hot, TP1, TP2, and/or TP3 opens and output
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5-5. Measuring Tuning Capacitor Voltage Significant AC voltage can remain on Turn Off power source and capacitors after unit is Off. Always disconnect input power. check ALL capacitors as shown to be Remove wrapper. sure they have discharged before 1 Tuning Capacitor C1 working on unit. 2 Tuning Capacitor C2 3 Tuning Capacitor C3 4 Voltmeter 4 Check tuning capacitors. Measure the ac voltage across the terminals on capacitors every 30 seconds until voltage is near 0 (zero) volts. Proceed with j
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5-6. Ground Fault Protection Ground fault protection circuitry automatically shuts down the power source output if a potentially hazardous condition exists at the heating device connected to the 1 power source (e.g. insulation has broken down on a heating blanket causing the conductor to come into contact with the workpiece or a heating coil touches the workpiece causing a short in the output circuit). The supplied ground lead must be connected between the workpiece and power source to provide p
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5-7. Measuring Input Capacitor Voltage Turn Off power source and Significant DC voltage can remain on disconnect input power. capacitors after unit is Off. Always check ALL capacitors as shown to be Remove wrapper. sure they have discharged before 1 Input Capacitor C2 working on unit. 2 Input Capacitor C1 3 Input Capacitor C4 4 Input Capacitor C3 5 Voltmeter Check input capacitors. Measure the dc voltage across the positive (+) and negative ( −) terminals every 30 seconds until 12 3 4 voltage
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5-8. Diagnostic LED’s 1 Diagnostic LED’s 1 Use diagnostic LED’s to determine operating condition of power source. 2 Current Source Limit: 110 A Fault: 115 A 3 Over Frequency Limit: 50 kHz Fault: 55 kHz 4 Under Frequency Limit: 10 kHz Fault: 5 kHz 5 Current Reactive Limit: 700 A 6 Tank Voltage Limit: 670 V Fault: 1100 V Peak 7 Line Voltage Fault: ±20 % 8 Contactor Lights when contactor is energized. 9 Over Temp Lights when contactor is energized and over temperature condition is FAULT LIMIT prese
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5-9. Troubleshooting Trouble Remedy No heat output. Replace building line fuse or reset circuit breaker. Secure head/coil connecting plate to power source connecting block (see Section 3-2). Check and replace Power switch if necessary. Connect power source to proper input voltage or check for low line voltage. No heat output; fan motor continues to run. Safety interlock switch open. Reinstall wrapper (see Section 5-4). Thermostat(s) TP1, TP2, and/or TP3 open (overheating). Allow fan to run; the
