Miller Electric IH, TS User Manual

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Page 1

OM-203 185F

2005−09

Processes

Induction Heating

Description

Single Induction Heating Power Source Temperature Control/Recorder

IH/TS

Visit our website at

www.MillerWelds.com

File: Induction Heating

Page 2

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 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 Owner’s 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

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

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.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

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 or individual specification 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.

Mil_Thank 4/05

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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, Operation, and Maintenance 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − MESURES DE SECURITE POUR LE CHAUFFAGE PAR INDUCTION 4 . . . . . . . . . . . . . . . . . . .

2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien 5 . . . . . . . . . . . . . . . . . . .

2-2. Informations concernant les champs électro-magnétiques (Information EMF) 6 . . . . . . . . . . . . . . . . . . .

2-3. PRINCIPALES NORMES DE SÉCURITÉ 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. IH/TS Installation 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Connecting To Power Source 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Input 14 Pin Information For Receptacle RC1 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting 25kW System Cords And Cables 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting 5kW System Cords And Cables 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Connecting External Device 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − COMPONENTS AND CONTROLS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. IH/TS Front Panel 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. IH/TS Rear Panel 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Controller 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − SETUP AND OPERATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Safety Equipment 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. IH/TS Setup 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-1. Select Power Source 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2. Time Date Setup − Digital 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-1. Digital Recorder Controls 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-2. Login As Engineer 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-3. Go To Operator Screen 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-4. Locale Setup 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-5. Time And Date Setup 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-6. Login As User 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-7. Go To Home Screen 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-2-8. Channel Cycling On/Off And Notes 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Operation 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-1. 2408 Controller 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-1-1. 2408 Controller Operation 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-2. Programming The 2408 Controller 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3. Batch Recording Using 5100 Digital Recorder 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-1. Login As User 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-2. Start Recording 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-3. Stop Recording 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-4. Saving Data To A Disk (Recommended After Each Batch) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5. Saving Data To A PC (Alternative To Floppy Disk) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-1. Review Software − First Time Setup 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-2. Creating A Shortcut − First Time Setup 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-3. Changing IP Address To Connect The IH/TS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-4. Downloading Files From Recorder 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-5. Troubleshooting Connection Problems 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-3-5-6. Resetting IP Address (Necessary To Connect User’s PC To Company’s Network) 29 . . . . .

6-3-4. Running A Program To Preheat Or Stress Relief 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

6-3-5. Recovering From An Interruption 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-6. Viewing Data In Review Software 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-6-1. Installing Review Software And First Time Setup 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-6-2. Backing Up The Database 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-7. Running Review Software 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3-8. Typical Profile Chart Printout 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − CONFIGURING CONTROLLER AND RECORDER 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Changing Controller Operating Window, Ramp, Dwell, Or Temperature Units 48 . . . . . . . . . . . . . . . . . . . .

7-2. Changing 5100V Recorder From Degrees F to Degrees C And Change TC Descriptor 49 . . . . . . . . . . .

7-3. Restoring Recorder Configuration From A Floppy Disk

(For 5100 Digital Recorder) 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3-1. Load File 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3-2. Date Setup 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3-3. Time Setup 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3-4. Login As User 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3-5. Go To Home Screen 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Troubleshooting 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Diagnostic Procedures For IH/TS 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Resetting All RAM Variables In The Event Of Display Errors 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Factory Set Parameters 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-1. Controller Version Number 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-2. 2408 Controller Edit Parameters 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-3. 2408 Controller Full Parameters (Prior To Version V4.09) 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-4. 2408 Controller Configure Parameters (Prior To Version V4.09) 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-5. 2408 Controller Full Parameters (Effective w/Version V4.09) 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5-6. 2408 Controller Configure Parameters (Effective w/Version V4.09) 64 . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Calibration Certification Procedure 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Page 5

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE

USING

Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

safety_ihom 5/05

Y Marks a special safety message.

. Means “Note”; not safety related.

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 1-5. 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

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 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, see ANSI Z49.1 listed in Safety Standards. And, do not work alone!

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 Owner’s

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.

the output is on. The input power circuit and machine

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.

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 in inverter-type power sources after removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any internal parts.

FUMES AND GASES can be hazardous.

Induction Heating of certain materials, adhesives, and fluxes can produce fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation to re-

move fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s 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 oper-

ations. 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 while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if overheated. See coating MSDS for temperature information.

OM-203 185 Page 1

Page 6

FIRE OR EXPLOSION hazard.

INDUCTION HEATING can cause burns.

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.

D Allow cooling period before handling parts or equipment. D Keep metal jewelry and other metal personal items away from

head/coil during operation.

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.

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.

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.

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.

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.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent 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.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine Miller/Hobart replacement

parts.

For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other reproductive harm.

Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3.

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org).

OM-203 185 Page 2

Page 7

1-6. EMF Information

Considerations About Induction Heating And The Effects Of Low Frequency 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 scientific 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 offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

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:

Pacemaker wearers consult your doctor before welding or going near welding or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

OM-203 185 Page 3

Page 8

SECTION 2 − MESURES DE SECURITE POUR LE

CHAUFFAGE PAR INDUCTION

ihom_fre 8/03

AVERTISSEMENT

LE CHAUFFAGE PAR INDUCTION peut être dangereux.

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 condition de prendre certaines mesures. Les consignes de sécurité indiquées ci-après ne sont qu’un 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 D’INSTALLATION, DE FONCTIONNEMENT, DE MAINTENANCE ET DE REPARATION NE DOIVENT ETRE CONFIEES QU’A DU PERSONNEL QUALIFIE.

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 lorsqu’on active la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation 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 d’isolation secs, sans trous, et une protection corporelle.

4. Isolez-vous de la pièce et du sol avec des tapis ou des couvertures d’isolation suffisamment grands pour prévenir tout contact physique avec la pièce ou la terre.

5. Déconnecter l’alimentation avant d’installer l’appareil ou d’en effectuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation 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 l’isolement.

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 l’alimentation − contrôler et s’assurer que le conducteur de terre du câble d’alimentation 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 d’entrée brancher d’abord le conducteur de terre approprié − contrôler deux fois les connexions.

10. Vérifier souvent le bon état du câble d’alimentation ou l’isolation des fils − remplacer le câble immédiatement s’il est endommagé − des fils dénudés peuvent provoquer des accidents mortels.

11. Arrêter tous les équipements lorsqu’ils 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 d’une autre machine.

15. Utiliser seulement des équipements bien entretenus. Réparer ou remplacer immédiatement des composants endommagés. Effectuer des travaux d’entretien sur l’appareil 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 L’EQUIPEMENT.

LE CHAUFFAGE PAR INDUCTION peut provoquer un incendie.

1. Ne pas surchauffer les composants ni les adhésifs.

2. Attention aux risques d’incendie: tenir un extincteur à proximité.

3. Stocker des produits inflammables hors de la zone de travail.

1. Ne pas toucher ou manipuler la tête/l’enroulement à induction pendant le fonctionnement.

2. Tenir les bijoux et autres objets personnels en métal éloignés de la tête/de l’enroulement pendant le fonctionnement.

3. Laisser refroidir les composants ou équipements avant de les manipuler.

La mise en place de l’appareil sur, au-dessus ou à proximité de surfaces inflammables peut être source d’INCENDIES OU d’EXPLOSION.

1. Ne pas placer l’appareil sur, au-dessus ou à proximité de

surfaces infllammables.

2. Ne pas installer l’appareil à proximité de produits inflammables

3. Ne pas faire fonctionner l’appareil en atmosphère explosive.

OM-203 185 Page 4

Page 9

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 l’interieur, 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 d’air 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 s’il 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 l’air, abaisser le niveau d’oxygène, et provoquer des lésions ou des accidents mortels. S’assurer que l’air ambiant ne présente aucun danger.

6. Ne pas chauffer dans des endroits se trouvant à proximité d’opérations 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 d’un revêtement tels que l’acier 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 s’ils sont chauffés.

2-1. Dangers supplémentaires de mise en route, de fonctionnement et d’entretien

LA CHUTE DE MATERIEL peut provoquer des blessures personnelles graves et endommager les équipements.

1. Utiliser la poignée et demander à une personne ayant la force physique nécessaire pour soulever l’appareil.

2. Déplacer l’appareil à l’aide d’un charriot ou d’un engin similaire.

3. Pour les appareils sans poignée utiliser un équipement d’une capacité appropriée pour soulever l’appareil.

4. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

UNE UTILISATION INTENSIVE peut provoquer 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.

L’ELECTRICITE STATIQUE peut endommager les composants des tableaux électriques.

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.

LA PROJECTION DE PIECES DE METAL ou DE COLLE peut provoquer des blessures aux yeux.

1. Porter des lunettes de protection avec des protections latérales.

DES ORGANES MOBILES peuvent provoquer des blessures.

1. S’abstenir de toucher des organes mobiles tels que des ventilateurs.

2. Maintenir fermés et fixement en place les portes, panneaux, 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 d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de chauffage à induction.

Il subsiste DU COURANT CONTINU IMPORTANT après la mise hors tension de l’alimentation électrique.

1. Avant de toucher des organes internes, arrêter la source électrique, débrancher l’alimentation, et décharger les condensateurs d’alimentation conformément aux instructions indiquées dans la partie maintenance.

LE RAYONNEMENT HAUTE FREQUENCE peut provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.

• Demander seulement à des personnes qualifiées

familiarisées avec des équipements électroniques de faire fonctionner l’installation.

• L’utilisateur est tenu de faire corriger rapidement par

un électricien qualifié les interférences résultant de l’installation.

• Si le FCC signale des interférences, arrêter immé-

diatement l’appareil.

• Effectuer régulièrement le contrôle et l’entretien de

l’installation.

• Maintenir soigneusement fermés les portes et les

panneaux des sources de haute fréquence.

OM-203 185 Page 5

Page 10

2-2. 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 d’importantes 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 d’une très grande qualité, les résultats sont complexes. La compréhension scientifique courante ne nous permet pas encore d’interpréter 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 d’un côté à distance de l’opérateur

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 l’opérateur.

En ce qui concerne les stimulateurs cardiaques

Les procédures ci-dessus concernent également les porteurs de stimulateur cardiaque. Consulter votre médecin pour un complément d’information.

2-3. 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-203 185 Page 6

Page 11

SECTION 3 − INTRODUCTION

The Induction Heating Temperature Station (IH/TS) is designed to be used with Induction Heating Systems for pre-heat and post-heat (stress relieving) applications. The station is built in two different configurations; as a controller only or as a controller with a digital recorder.

The controller in the IH/TS comes pre-programmed from the factory with a typical stress relieving temperature profile that can be easily changed to match specific customer stress relief requirements. Also, the controller can be programmed to operate in a pre-heat mode. These instructions will guide the operator in the proper use of the station which includes programming and setting up the controller, and operating the recorder.

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Page 12

SECTION 4 − INSTALLATION

4-1. Specifications

Specification Description

Overall Dimensions Height: 10 in (254 mm); Width: 14-1/2 in (368 mm); Depth: 16 in (406 mm)

Weight Net: IH/TS (no recorder) 13.1 lb (5.9 kg); IH/TS (digital recorder) 21.1 lb (9.6 kg)

Type Of Input Power 24 Volts DC, 115 Volts AC

Memory Capacity One Program Up To 8 Segments

Control Capacity Single Power Source Control Operating Temperature Range 41° To 104° F (5° To 40° C) Storage Temperature Range −4° To 122° F (−20° To 50° C)

Reference the controller and recorder manuals for additional information.

4-2. IH/TS Installation

Y Turn Off and disconnect

input power.

5 kW System

1. Temperature Control/Recorder

2. 5kW Mounting Bracket

3. Screw, 10-32 (4)

Install and secure IH/TS to mounting bracket using supplied #10 screws.

4. 5kW Power Source Case

5. Case Sheet Metal Screw (4)

Remove case sheet metal screws from both top left and right sides of unit. Install mounting bracket to power source and secure by reinstalling sheet metal screws.

25 kW System

6. 25 kW Power Source Case

7. Rear Mounting Bracket

8. Screw, 1/4-20 (2)

Remove front and middle mounting screws from top of Item 6 case. Locate IH/TS and reinstall front mounting screws. Locate rear mounting bracket, and secure with supplied 1/4-20 screws. Reinstall middle mounting screws to secure bracket to case.

Tools Needed:

OM-203 185 Page 8

3/8, 5/16 in

Ref. 802 905-A / 802 900

Page 13

4-3. Connecting To Power Source

Turn Off power source.

1. IH/TS

I H

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 4-4)

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.

sb7.1* 3/93 - Ref. S-0004-A / S-0750 / Ref. 802 926 / Ref. 801 049 / 801 825-B / Ref. 803 004-A

4-4. Input 14 Pin Information For Receptacle RC1

REMOTE 14

emote Contactor

emote Output Contro

Power Source Fault

emote Metering

*See power source Owner’s Manual for scaling information.

Pin Pin Information

A +24 volts dc from power source.

B Contact closure to A completes power source +24 volts dc contactor control circuit.

D Control circuit common.

E 0 to +10 volts dc signal for power source output control.

F, J Absence of contact closure from power source indicates power source output failure.

I Actual frequency input signal.

L Average power input signal.

M Voltage input signal RMS.

N Current input signal RMS.

OM-203 185 Page 9

Page 14

4-5. Connecting 25kW System Cords And Cables

Blue

Hose From Cooler To

Power Source

14-Pin

Control Cable

Yellow

Front Rear

110 Volt From

Cooler

Output

Connectors

Blue

Hose From

IH/TS To

Cooler

Red

Yellow

Hose

From Power

Source

To IH/TS

110 Volt From

IH/TS

Red

Connect the power output cable and coolant lines as shown.

Connect 110-volt power cable as shown. Plug the 110-volt cooler power cord into

the duplex at the rear of the power source cart. On the 25kW system, the cooler must be plugged into the right side duplex. This is identified with a label that reads “switched receptacle.” The ON-OFF switch located to the left operates this

plug. The IH/TS Control is plugged in the left

side duplex. Do not use these duplex connections for operating auxiliary tools, such as grinders, drills, lights, etc.

Connect output power cables to the output connectors.

. All coolant connections have 5/8-18

left-hand threads.

803 036-C

D Connect the “coolant out” line from

the cooler directly to the output extension cable.

D Connect the “coolant in” line on

the IH/TS directly to the remaining output extension cable connection.

D Connect the “coolant out” line from

the IH/TS to the “coolant in” line on the cooler.

OM-203 185 Page 10

Page 15

4-6. Connecting 5kW System Cords And Cables

Front Rear

Output

Connectors

Hose From

Output Extension Cable

To IH/TS

Hose From IH/TS To

Cooler

Connect the power output cable and coolant lines as shown.

Connect 110-volt power cable as shown.

Plug the 110-volt cooler power cord into the duplex at the rear of the power source cart.

Hose From Cooler To

Output Extension Cable

The IH/TS Control is plugged in the left side duplex. Do not use these duplex connections for operating auxiliary tools, such as grinders, drills, lights, etc.

D Connect the “coolant out” line from

the cooler directly to the output extension cable.

803 040-A

D Connect the “coolant in” line on

the IH/TS directly to the remaining output extension cable connection.

D Connect the “coolant out” line from

the IH/TS to the “coolant in” line on the cooler.

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Page 16

4-7. Connecting External Device

The IH/TS must have (as a minimum) one thermocouple connected to receptacle TC1. If multiple thermocouples are desired, either use individual thermocouple plugs or the

thermocouple extension cable. To connect thermocouples to the

control, proceed as follows: Turn Off power source.

1. Temperature Controller

2. Thermocouple Receptacles

3. Individual Thermocouple Plug

4. Thermocouple Extension Cable

Align plug pins with receptacle sockets and push plug into receptacle.

5. Coolant Line From Coil

6. Coolant Line To Cooler “Coolant In” Port

The IH/TS is supplied with an internal coolant flow switch. Coolant hoses must be connected to the IH/TS for proper operation. Connect coolant hoses (supplied with post-heat systems) to coolant fittings on unit as described in Section 4-5.

Tools Needed:

OM-203 185 Page 12

11/16 in

Ref. 803 003-B

Page 17

SECTION 5 − COMPONENTS AND CONTROLS

5-1. IH/TS Front Panel

Y Keep all panels, doors, and

covers closed and secure during programming.

1. Temperature Controller

2. Parameter Display Screen

3. Heat On Pilot Light

4. Fault/ Limit Light

5. Run Button

6. Hold Button

7. Stop Button

8. Recorder (If Equipped)

Ref. 803 004

OM-203 185 Page 13

Page 18

5-2. IH/TS Rear Panel

4 5 6

Y Keep all panels, doors, and

covers closed and secure during programming.

1. Thermocouple Connectors

2. On/Off Power Switch

3. 115 VAC Power Cord

4. 14-Pin Receptacle

5. Coolant Flow Switch “IN” Fitting

6. Coolant Flow Switch “OUT”

Fitting

7. Power Source Select Switch

8. Network Connection

OM-203 185 Page 14

Ref. 803 004-A

Page 19

5-3. Controller

Y Keep all panels, doors, and

covers closed and secure during programming.

OP1

200.0

SP2

AUTO MAN

RUN HOLD

B Y

1. Digital Display

2. Page Forward Button

3. Scroll Button

4. Down Button

5. Up Button

6. Actual Temperature

7. Setpoint Temperature

8. Auto/Man Button (Disabled)

9. Run/Hold Button (Disabled)

345

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Page 20

SECTION 6 − SETUP AND OPERATION

6-1. Safety Equipment

Wear the following during operation:

1. Dry, Insulating Gloves

2. Safety Glasses With Side Shields

DO NOT wear rings or watches during operation.

sb3.1* 1/94

6-2. IH/TS Setup

6-2-1. Select Power Source

Energize the power source, cooler, and IH/TS. A power source selection will appear in the top right corner of the IH/TS front panel Parameter Display. Press the recessed Power Source Select button on the IH/TS rear panel to toggle through and select the appropriate power source maximum output. This selection will provide the proper output scaling in the parameter display screen for the power source that is attached to the IH/TS.

Parameter Display

0 . 0 K W P w r PS 2 5

0Amps (rms) 0Volts (rms)

12 .5 KHs Fr equency

Power Source Max Output

OM-203 185 Page 16

Page 21

6-2-2. Time Date Setup − Digital

6-2-2-1. Digital Recorder Controls

3 2 1

Y Keep all panels, doors, and

covers closed and secure during programming.

1. Page Up

2. Page Down

3. Left

4. Right

5. Option

6. Menu

Additional keys that appear as

needed for specific applications are

as follows:

7. Close Folder

8. Open Folder

9. Left Cursor

10. Right Cursor

6-2-2-2. Login As Engineer

1. Touch top left corner (Logged Out) or (User).

2. Touch Blue text (pull down menu) next to User.

3. Touch Engineer.

4. Touch Password field.

5. Touch Numeric.

6. Touch 1, then 0, and finally Ok. “Engineer” will appear in top left corner of display.

6-2-2-3. Go To Operator Screen

1. Touch the Menu key in bottom right corner to open Root Menu.

2. Touch Operator.

6-2-2-4. Locale Setup

1. Touch System.

2. Touch Locale.

3. Touch pull down next to Country.

4. Touch appropriate country.

5. Touch pull down next to Time Zone.

6. Touch appropriate time zone (i.e. CST Central). See “http://www.timeanddate.com” for additional information.

7. Set DST (Daylight Savings Time) if applicable. Place an “X” in the box next to “Use Summertime (DST)” to enable this option.

OM-203 185 Page 17

Page 22

NOTE

In general, for those locations that observe DST: DST begins at 2:00 am on the first Sunday in April. DST ends at 2:00 am on the last Sunday in October. See “http://deil.lang.uiuc.edu/web.pages/holidays/DST.html for exceptions.

8. Touch Apply.

6-2-2-5. Time And Date Setup

1. Touch System.

2. Touch Clock.

3. Adjust time and date, if necessary.

4. Touch Apply.

6-2-2-6. Login As User

1. Touch top left corner (Engineer).

2. Touch pull down next to User.

3. Touch User from pull down list.

6-2-2-7. Go To Home Screen

1. Touch the Menu key in bottom right corner to open Root Menu.

2. Touch Home.

6-2-2-8. Channel Cycling On/Off And Notes

When Trend graphs are displayed, the operator has the option to sequentially display the TC readings for each channel by activating the “Channel Cycling On”option. When channel cycling is off, recorder displays only the selected TC value.

To activate/deactivate “Channel Cycling”:

1. Press the Option key to open options menu.

2. Press channel cycling On to activate cycling or press channel cycling Off to deactivate cycling.

To manually change which TC is displayed, press the TC field to advance to the next TC reading.

Notes can be added to a chart on the recorder while viewing a trend screen.

Press the “Option Menu” button. Press “Note”. Press the field next to “User Note”

and enter notes using keypad. Press “OK”. Press “OK”. The note is added to the chart. The note can be viewed on the

bottom of the screen or in the history screen.

Press the Option key, press “Enter History”.

To exit, press the Option key, then press “Exit History”.

OM-203 185 Page 18

scrn34

Page 23

6-3. Operation

1. Energize IH/TS and power source. A coolant flow error should appear on the IH/TS display. Energize the cooler and the error will clear from the display.

2. Set up Temperature Profile − per code requirements (see Section 6-3-2 Programming The 2408 Controller).

3. Set up and start Digital Recorder

Digital Recorder (see Section 6-3-3. Batch Recording On The 5100 Digital Recorder)

4. Run the heat process (see Section 6-3-4. Running A Heat Treat and the following tables).

5. Recover from an interruption, if applicable (see Section 6-3-5. Recovering From An Interruption).

6. Retrieve data

Digital Recorder (see Section 6-3-3-4. Batch Recording On The 5100 Digital Recorder)

View and print data (see Section 6-3-6 Review Software).

Table 6-1. Controller Display Definitions

Name Description

Home List (extra parameters may be present.)

Home Measured value and Setpoint

% Output level

Table 6-2. Run List Sub-Menu Definitions

run program run List

StAt Program status (OFF, run, hoLd, HbAc, End) PSP SEG StyP SEG.t tGt rAtE PrG.t SEG.d FASt

*This parameter can only be changed when the program is in reset.

Programmer setpoint

Active segment number

Active segment type

Segment time remaining in the segment units

Target setpoint

Ramp rate (if a rate segment)

Program time remaining in hours

*Flash active segment type in the lower readout of the home display (no/YES)

Runs through program 10 times faster than normal

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6-3-1. 2408 Controller

The 2408 controller in the IH/TS provides a means of establishing a heat profile for heating or stress relieving as dictated by “code” requirements, and controls the power source to meet the programmed profile. The 2408 controller has several screens (main and sub-menu) that are used to monitor status and program the control. The main screens are as follows:

Home Screen: This screen is displayed after first turning on the unit. It has the actual temperature at the top of

the display and program temperature at the bottom of the display. Home Screen sub-menu and definitions are shown in Table 6-1. Pressing the “Scroll”

sub-menus.

Run List: This screen is accessed by pushing the “Page” key twice. Run List allows the operator to

check the status of a program while the system is running. It also allows making changes to a program by pressing the “Hold” button on the front of the IH/TS. Run List sub-menu

screens and their definitions are shown in Table 6-2.

Program List: This screen is accessed by pushing the “Page” key three times. Program List is used to

program the controller for a pre-heat or stress relieving temperature profile. Definitions of the various terms found in the sub-menu screens are shown in Table 6-3. Typical programming examples are shown in Figure 6-1, Figure 6-2 and Figure 6-3.

Access List: This screen is used to access the configuration and set-up sub-screens within the controller. This

area is password protected and should only be used by an experienced operator.

button will step through the

. Making changes in the Access List screens may cause the system to operate incorrectly.

A series of keys at the bottom of the 2408 controller are used to navigate between and change values in the various screens on the controller display. Definition of the keys are as follows:

The “Page” key advances the controller display between main screens (Run List, Prog List and Accs List).

The “Scroll” key advances between various sub-menu screens in the main menus.

The “Up”

and “Down”

keys are used to change values in the sub-menu screens.

. The two small round buttons on the front of the controller are disabled and nonfunctional.

6-3-1-1. 2408 Controller Operation

The 2408 controller is configured to control the power source to achieve the temperature program that is entered in “Prog List”. The configuration of the controller contains two important elements that dictate how the controller switches between segments and how it protects against over-temperature conditions.

One element is called “Holdback”. This is a temperature window that the controller uses to determine the point at which it switches from segment-to-segment. The window is set to ±10°. When operating within a temperature profile, the controller will not advance to the next segment until the actual temperature comes within 10° of the target temperature.

The second element is an alarm. This alarm value is set at 25° F. When the actual temperature exceeds the target temperature by 25° F, the controller shuts off the power source contactor to prevent overheating the part. When the temperature falls 2° F below the alarm temperature, the controller re-energizes the power source output.

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6-3-2. Programming The 2408 Controller

Identify the “code” requirements for the heat treat. For Preheat program refer to Figure 6-1. For Postweld stress relief program refer to Figure 6-2. For a complex stress relief program (multiple temperature rise and cool rates) refer to Figure 6-3. Use worksheet in Figure 6-4 to help prepare either a pre- or post-heat temperature profile.

Table 6-3. Program List Terms And Definitions

SEG.n

Step (StEP)

Segment number

Segment Type Definitions

The setpoint steps instantaneously from its current value to a new value.

Dwell (dwEl)

Ramp Time (rmP.t) Ramp Rate (rmP.r)

End (End)

The following parameters are available depending on the tYPE selected

The setpoint remains constant for a specified period.

Dwell units (dwL.U) are in hours.

The setpoint ramps linearly, from its current value to a new value, either at a set rate (called ramp-rate programming), or in a set time (called time-to-target programming). You must specify the ramp rate, or the ramp time, and the target setpoint, when creating or modifying a program. Ramp units (rmP.U) are in hours.

A program either ends in this segment or repeats. You specify which is the case when you create or modify a program (see the final topic in this chapter). When a program ends, the programmer is put into either a continuous Dwell state with all outputs staying unchanged, or the Reset state.

StEP dwEl rmP.t rmP.r End

tGt √ √ √ Target setpoint for a “rmP“ or “StEP” segment. rAtE √ Ramp rate for a “rmP.r” segment. dur √ √ Dwell time for a “dwEl” segment. End.t √ End of prog − dwEl, rSEt, S OP.

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Step to 300° F

as fast as

possible

Dwell @ 300° F

for 8 hours

Free fall to

ambient

SEG.n

tYPE

StEP

(step)

tGt

300

(deg)

SEG.n

tYPE

dwEl

(soak)

dur

8.0

(in hrs)

SEG.n

tYPE

End

(end)

End.t S OP

(sets output to 0)

Example Pre−heat Profile

350 300 250 200 150

Degrees F

100

0 102030405060

Time (minutes)

Figure 6-1. Setting Pre-heat Profile Using Example Parameters

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Step to 600° F

as fast as

possible*

Ramp to 1350° F

@ 600° /hr

Dwell @ 1350°

F for 1/2 hour

Ramp to 600° F

@ 600° /hr

Free fall to

ambient

SEG.n

tYPE StEP

(step)

tGt

600

(deg)

SEG.n

tYPE

rmP.r

(ramp rate)

tGt 1350

(deg)

rAtE

600

(deg/ hr)

1400 1200 1000

800 600

Degrees F

400 200

SEG.n

tYPE

dwEl

(soak)

dur

0.5

(in hrs)

SEG.n

tYPE

rmP.r

(ramp rate)

tGt

600

(deg)

rAtE

600

(deg/hr)

Example Stress Relief Profile

0 30 60 90 120 150 180

Time (minutes)

210 240 270

SEG.n

tYPE

End

(end)

End.t

S OP

(sets output to 0)

. *On small diameter pipe, it may be necessary to reduce the

output of the power source to achieve a “reasonable rate” in Segment 1; thereafter, the program controls the rate of temperature rise and the output power may be increased to full if desired. To reduce output power, turn power source output knob to desired setting.

Figure 6-2. Setting Stress Relief Profile Using Example Parameters

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Step to

600° F as

fast as

possible

Ramp to 800° F

@ 400° /hr

Ramp to 1250° F

@ 200° /hr

Dwell @ 1250° F

for 1 hour

Ramp to 800° F

@ 200° /hr

Ramp to 600° F

@ 400° /hr

Free fall to

ambient

SEG.n

tYPE StEP

(step)

tGt

600

(deg)

SEG.n

tYPE

rmP.r

(ramp rate)

tGt

800

(deg)

rAtE

400

(deg/ hr)

1400 1200 1000

800 600

Degrees F

400 200

SEG.n

tYPE

rmP.r

(ramp rate)

tGt

1250

(deg)

SEG.n

tYPE

dwEl

(soak)

dur

1.0

(in hrs)

rAtE

200

(deg/ hr)

Example Multi−Step Stress Relief Profile

0.0 1.0 2.0 3.0 4.0 5.0 6.0 Time (hours)

SEG.n

tYPE

rmP.r

(ramp rate)

tGt

800

(deg)

rAtE

200

(deg/hr)

7.0

SEG.n

tYPE

rmP.r

(ramp rate)

tGt

600

(deg)

rAtE

400

(deg/hr)

SEG.n

tYPE

End

(end)

End.t S OP

(sets output to 0)

. *On small diameter pipe, it may be necessary to reduce the

Figure 6-3. Setting A Complex Stress Relief Profile With Multiple Temperature Rise/Cool Rates

Using Example Parameters

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rAtE

TGT

rAtE

TGT

SEG.n

tYPE

StEP

(step)

TGT

(target)

(deg)

(°/hr)

dur

(°/hr)

TGT

(hrs)

SEG.n

tYPE

rmP.r

(ramp rate)

TGT

SEG.n

tYPE

dwEl

(soak)

dur

SEG.n

tYPE

rmP.r

(ramp rate)

TGT

SEG.n

tYPE

End

(end)

End.t

S OP

(target)

(deg)

rAtE

(duration in hrs)

(target)

(deg)

rAtE

(sets output to 0)

(deg/hr)

1. Identify Target temperatures, Ramp Rates, and Dwell Time.

2. Insert Values into profile.

(deg/hr)

3. Program controller with Profile using Navigating buttons:

Press “Page” button until “ProG LiSt” appears on the display.

Figure 6-4. Profile Set-Up Worksheet

Press “Scroll” button to advance to each screen.

Press “Up” or “Down” button to change values.

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6-3-3. Batch Recording Using 5100 Digital Recorder

The batch file generated by the recorder will consist of:

GroupDescriptor~BatchName~TimeDateStamp.uhh

The default Group Descriptor is set to “Group”. This setting may be changed to something that relates to the application (i.e. Company, Contract, or Project name).

To change the Group Descriptor, proceed as follows:

1. Log in as an Engineer (see Section 6-2-2-2).

2. Touch Menu (bottom right).

3. Touch Operator.

4. Touch Config.

5. Touch Groups.

6. Touch the field next to Descriptor, a keypad will appear on the display.

7. Enter the desired name and touch Ok.

8. Touch Apply.

9. Touch Menu (bottom right).

10. Touch Home.

The Batch Name is entered by the operator. This should be a unique name that identifies the part being heated. Since the same part may have Pre-heat (P), Bakeout (B), and Stress (S) procedures done to it, the batch name should include an indicator as to which process was done (i.e. W41-1307-2-S) where the S indicates a stress procedure.

The Time Date Stamp and .uhh file extension are both generated automatically by the recorder.

Begin Batch recording.

6-3-3-1. Login As User

1. Touch top left corner.

2. Touch pull down next to User.

3. Touch User from pull down list.

6-3-3-2. Start Recording

1. Touch “No Batch In Progress”.

2. Touch “New”.

3. Touch field next to Job # (Batch Name). This will be the batch name.

4. Enter unique Batch Name (see Section 6-3-3).

5. Touch “Ok”.

6. Touch field next to User ID.

7. Enter User ID.

8. Touch “Ok”.

9. Touch field next to Comments.

10. Enter Comments or, at least, touch the blank key.

11. Touch “Ok”.

12. Scroll down to bottom of screen.

13. Touch field next to Rec. ID.

14. Touch the blank key (bottom right keyboard).

15. Touch “Ok”.

16. Touch “Start”.

17. Touch “Close”.

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6-3-3-3. Stop Recording

1. Touch the block with the batch name.

2. Touch “Stop”.

3. Touch “Close” − screen returns to the home screen and displays “No Batch In Progress”.

NOTE

6-3-3-4. Saving Data To A Disk (Recommended After Each Batch)

1. Insert floppy disk into recorder.

2. Login as User (see Section 6-3-3-1).

3. Touch key in bottom right corner to open Root Menu.

4. Touch “Operator”.

5. Touch “Archive”.

6. Touch “Disk”.

7. Select how much data to save to floppy (typically, Last Day is sufficient). Last day saves from 12:00am until current time. Last week saves from 12:00am Monday until current time. Scroll down and wait until archive transfer changes from active to inactive.

NOTE

8. Touch key in bottom right corner to open Root Menu.

If a batch file was not started, the temperature data is still recorded. The Job# (Batch Name), User, Comments, and Recorder ID are not recorded.

DO NOT remove floppy disk before completion of data transfer.

9. Touch “Home”.

10. Remove floppy disk.

11. To view data, go to Section 6-3-6.

6-3-3-5. Saving Data To A PC (Alternative To Floppy Disk) 6-3-3-5-1. Review Software − First Time Setup

1. Start “Review” software (see Section 6-3-7).

2. Click on “Instrument”, “Setup”, “TCP/IP”.

3. Click on “Add Instrument”.

4. In the “TCP/IP Address or Host Name:” field, type “192.168.111.222”.

5. In the “Identifier:” field, type “Generic”.

6. Click on “OK”.

6-3-3-5-2. Creating A Shortcut − First Time Setup

Local Area Network Connection (Windows) 2000)

1. Click on “Start”, “Settings”, “Control Panel”.

2. Open “Network and Dial-up Connections”.

3. Right click on “Local Area Connection”.

4. Select “Create Shortcut”.

5. Click on “Yes” to create a shortcut on the desktop.

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6. Close the “Network and Dial-up Connection” window.

7. Close the “Control Panel”.

Network Connection (Windows) 95, 98, ME)

1. Click on “Start”, “Settings”, “Control Panel”.

2. Right click on “Network”.

3. Select “Create Shortcut”.

4. Click on “Yes” to create a shortcut on the desktop.

5. Close the “Control Panel”.

6-3-3-5-3. Changing IP Address To Connect The IH/TS

For Windows) 2000

1. Close any open network applications.

2. Double click “Local Area Connection” desktop shortcut.

3. Click on “Properties”.

4. Scroll down to “Internet Protocol (TCP/IP)”.

5. Click on “Internet Protocol (TCP/IP)” to highlight it.

6. Click on “Properties”.

7. Click on “Use the following IP address:”.

8. In the “IP address” field, type “192.168.111.221”.

9. Click on “OK”.

10. Click on “OK” to add the subnet mask.

11. The “Subnet mask:” field should display “255.255.255.0”.

12. Click on “OK”.

13. Click on “OK”.

14. Click on “Close” to close the “Local Area Connection” window.

For Windows) 95, 98, ME

1. Close any open applications (Windows will restart to apply settings).

2. Double click “Network” desktop shortcut.

3. Scroll down to “Internet Protocol (TCP/IP)”.

4. Click on “Internet Protocol (TCP/IP)” to highlight it.

5. Click on “Properties”.

6. Click on “Specify an IP address:”.

7. In the “IP address” field, type “192.168.111.221”.

8. Click on “OK”.

9. Click on “OK”.

10. Click on “Yes” to restart the computer and have changes take effect.

6-3-3-5-4. Downloading Files From Recorder

1. Connect a crossover cable between the IH/TS recorder and the PC (a crossover cable is a special network

cable with pins 2 and 3 reversed on one end).

2. Start “Review” software (see Section 6-3-7).

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3. Click on “Instrument”, “File Services”.

4. Click on “Generic”.

5. Enter user name: “user” (leave password field blank).

6. Click on “OK”.

7. Right click on desired files and transfer them following the procedures in Sections 6-3-6 and 6-3-7.

6-3-3-5-5. Troubleshooting Connection Problems

1. Click on “Start”, “Programs”, “Accessories”, “Command Prompt”.

2. Type in “ping 192.168.111.222”.

3. Press “Enter”.

If the message “Timed Out” appears 4 times, the recorder is not responding. Check unit setup outlined previously and verify crossover cable is connected properly.

6-3-3-5-6. Resetting IP Address (Necessary To Connect User’s PC To Company’s Network)

For Windows) 2000

1. Close any open network applications.

2. Double click “Local Area Connection” desktop shortcut.

3. Click on “Properties”.

4. Scroll down to “Internet Protocol (TCP/IP)”.

5. Click on “Internet Protocol (TCP/IP)” to highlight it.

6. Click on “Properties”.

7. Click on “Obtain an IP address automatically”.

8. Click on “OK”.

9. Click on “OK”.

10. Click on “Close” to close the “Local Area Connection” window.

For Windows) 95, 98, ME

1. Close any open applications (Windows will restart to apply settings).

2. Double click “Network” desktop shortcut.

3. Scroll down to “Internet Protocol (TCP/IP)”.

4. Click on “Internet Protocol (TCP/IP)” to highlight it.

5. Click on “Properties”.

6. Click on “Obtain an IP address automatically”.

7. Click on “OK”.

8. Click on “OK”.

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6-3-4. Running A Program To Preheat Or Stress Relief

To start the Heat Treat operation, proceed as follows:

Press the “RUN” button − The blue “Heat On” light turns on and the power source energizes.

The power source parameters are displayed on the “Parameter Display”. The controller flashes “Hold” until the measured temperature climbs to within the “Hold Back” window (10°) of the target temperature.

To adjust profile during the Heat Treat operation, proceed as follows:

Press the “HOLD” button − The controller displays “HOLD”, but the heat is maintained at the present target

temperature. Press

Press “Scroll” button to select the desired parameter for changing. Use

Press “Page” button until parameter screen appears on the display. Press “RUN” button to resume program.

When cycle completes or to abort the process, fully press the “STOP” button − controller resets to segment 1 and power source contactor relays open.

“Page” button until “ProG LiSt” appears on the display.

“Up” or “Down” button to change value.

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6-3-5. Recovering From An Interruption

Press the “RUN” button to start profile.

NOTE

There are two conditions the controller looks at to determine:

1) If it should supply output power and

2) If the power source contactor should be on.

1) If the current temperature is more than 105 F above the target temperature in segment 1, the IH/TS will not require output from the power source. The blue Heat On light will be on and power source will not provide output. (Providing the Panel/Remote switch on the power source is in the remote position.)

2) If the current temperature is more than 255 F above the target temperature in segment 1, the blue Heat On light will be off and the system will not provide power. (Regardless of Panel/Remote switch position.)

To continue from the current part temperature, rather than waiting for the part temperature to fall to within 10° of segment 1’s target temperature:

Press the “HOLD” button − The controller displays “HOLD”.

Press “Page” button until “ProG LiSt” appears on the display. Press “Scroll” button to SEG 1’s TGT temperature setting. Use

“Up” or “Down” button to adjust target temp to the current

temperature of +5° F. Press “Page” button until parameter screen appears on the display.

Press “RUN” button to resume program − the controller will step to the new target temperature setting and continue through the remainder of the profile.

OP1

200.0

SP2

AUTO MAN

34 5

RUN HOLD

B Y

106

Y Keep all panels, doors, and

covers closed and secure during programming.

1. 2408 Controller

2. Page Forward Button

3. Scroll Button

4. Run/Hold Indicator

5. Down Button

6. Up Button

7. Actual Temperature

8. Setpoint Temperature

9. Heat On Pilot Light

10. Fault/ Limit Light

11. Run Button

12. Hold Button

13. Stop Button

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6-3-6. Viewing Data In Review Software

6-3-6-1. Installing Review Software And First Time Setup

Insert the “Chessell 5000 Series Data Management System” CD into the computer. If the installation program does not automatically start, browse to the CD using “My Computer” and run

“Setup.exe”. Place a check in the box next to “Review”. The other components are optional. Additional information about the

software can be found in the readme.txt file on the CD. Click “Install Recorders Software” and accept the default settings of the software installation. This Owner’s Manual will guide you through the steps to create and save a chart for a batch file. Additional informa-

tion on the Review software is available under Start\Programs\Eurotherm\Manuals\Review Manual. The first time Review software is launched, a message box will be displayed to enable “Review Full features”. Place

a check in the box for “Don’t ask me this again”, then click “No”.

“Review” software first time setup screen.

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6-3-6-2. Backing Up The Database

When Review software is used, archive data is stored in a database on the PC. As files are transferred to the database, the “Review.erv” file size increases. Data transferred into the database can be deleted, but not moved. If the “Review.erv” file size reaches 1 gigabyte, data will need to be deleted or a new database will need to be created. Refer to the Review Manual for additional instructions.

When data is transferred to the review.erv database, the original.uhh data file is simultaneously copied to the Master Archive Folder.

To change the location of the Master Archive Folder, proceed as follows: In Review software, click “Options”. Click “Master Archive Folder”. Change the “Master Archive Folder” location as desired. If a network drive is available, multiple users can use the

same database. Refer to the Review Manual for further instructions.

Screens for changing the “Master Archive Folder” location.

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Page 37

There are three files used to produce a chart in Review software as follows:

1. The .uhh file contains the actual temperature data downloaded from the recorder.

2. The c:\Program Files\Eurotherm\Review\Review.erv file contains a copy of the original data and any annotations added in the Review software.

3. The .cgp file contains the chart graphical properties (setup).

To prevent loss of data due to software or hardware failure, all three file types should be backed up on a regular basis.

6-3-7. Running Review Software

Start “Review” software.

scrn1

Insert floppy disk with desired file into floppy drive on pc.

Select “File”. Select “Transfer Files”.

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Select “Files”.

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Select the “history” folder on the floppy drive or browse to the folder on the PC that contains the .uhh files.

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Single File With Batch Name

Select the desired file (highlight file name). The file name consists of:

Group_Descriptor∼Batch_Name∼Time/Date_stamp.uhh

For example: Miller~W41−1321−1−S~80098A200000014B.uhh

Select “Open”.

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Enter the Job# (Batch Name) in

the field next to “Select or Enter

Instrument tag:”

This is the “File name” the

information will be stored in.

Select “OK”.

Proceed to “New Instrument”

pop-up window (top of page 37).

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Single File With No Batch Name

Data is continuously stored in the recorder. If a batch was not started, the temperature

data is still recorded. The Job# (Batch Name), User, Comments and Recorder ID are not recorded. The file name would consist of: Group_Descriptor∼Time/Date_stamp.uhh (no Batch Name). The file creation time can be found using the Detail Button.

Select the desired file. Select “Open”.

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Enter the Job# (Batch Name) in

the field next to “Select or Enter

Instrument tag:”

This is the “File name” the

information will be stored in.

If a batch was not started, enter the Job# (Batch Name) in the field next

to “Enter Batch Name if Required:”

as well.

Select “Start Transfer”.

Proceed to “New Instrument”

pop-up window (top of page 37).

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Multiple Files With Batch Names

Multiple Files With No Batch Names

Data is continuously stored in the recorder. The file name consists of: Group_Descriptor∼Batch_Name∼Time/ Date_stamp.uhh

Select the desired files. Select “Open”.

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If a batch was not started, the temperature data is still recorded. The Job# (Batch Name), User, Comments and Recorder ID are not recorded. The file name would consist of: Group_Descriptor∼Time/Date_stamp.uhh (no Batch Name). The file creation time can be found using the Detail Button.

Select the desired files. Select “Open”.

scrn9

Select “All files from one instru- ment, automatic batch names”.

Enter the Job# (Batch Name) in the field next to “Select or Enter In- strument tag:“ This is the “File name” the information will be stored in.

Select “OK”. Proceed to “New Instrument”

pop-up window (top of page 37).

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New instrument is displayed. Select “OK” to add the Instrument

tag.

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Select “File”. Select “New Chart”.

Select “Add Point”.

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Select Instrument, this is the Instrument tag [Job# (Batch Name)] that was entered previously.

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Select the appropriate Log Group. Select Point ID to add a specific

point, then select “OK” or Select “Add All”.

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Change “Grid Major divisions:” to 30 resulting in 50° increments from 0-1500° F.

Select “OK” to view chart

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This display is the default view of the profile. Note the values show “No data” which is due to the dashed line on the right side of the screen being outside of the data values.

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Drag the slider on the left down to zoom the view out.

Click the maximize box to

enlarge to full screen.

Click on the profile,

the dashed line moves

to the cursor location.

The values at the cursor

location appear on the

right side of the screen.

. These steps must be done in

sequence for Batch information to display properly.

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Chart properties may be edited by selecting “Chart”, then “Setup”.

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To remove a TC, click on the TC# (Point ID), then click “Delete Point”.

To edit a TC trace properties, select a TC# (Point ID), then click “Point Properties...”.

Select “OK” to return to the chart.

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Span − dictates the range of temperature to plot for the trace.

Interpolation On − will show a smoothed line between points instead of steps.

Interpolation adds an “I” to end of descriptor.

Select “OK” when done.

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Comments can be added to the chart by selecting “Annotate” from the Chart Menu.

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Add comments in the Annotation field.

Add time manually. Select “OK”.

(10:56:00 AM)

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A warning will appear on the display stating that once added, the comment cannot be deleted or changed.

Select “OK”. The comment becomes part of the

chart.

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Save chart to floppy disk by selecting “File”, then select “Save chart As...”

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Select a path to “Save in”. Enter “File name” to save as.

. File name should be the same

as the Instrument name and Job# (Batch Name) for consistency.

Select “Save”.

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The file name becomes

part of the chart

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Select “File”. Select “Print” to print entire profile

on one page.

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Select “Batch”. Click in check box to select “Print

entire batch”. Select “Batch Name“ from pull

down menu. Select “Print”.

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6-3-8. Typical Profile Chart Printout

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Page 52

SECTION 7 − CONFIGURING CONTROLLER AND RECORDER

7-1. Changing Controller Operating Window, Ramp, Dwell, Or Temperature Units

NOTE

Press Page to

AccS LiSt

codE

Use the following instructions if changes are required to Operating Window, Ramp, Dwell, or Temperature units.

Wait 2 sec.

codE PASS

Goto OPEr

Y to

Goto Ful

ProG LiSt

toB

Goto ConF

toB

Goto Edit

toB

Goto Ful

ConF

Wait 2 sec.

ConF PASS

Y B

to change the operating Window ± units

to change Ramp units Hour, min or SEc

to change Dwell units

Hour, min or SEc

Hb bAnd

Hb U

rmP.U Hour

dwL.U Hour

Accs LiSt

CodE PASS

CodE

ConF

unit

Y B

to change the operating Temperature units to F, C or k

Exit

YES

Wait 2 seconds Controller resets

OM-203 185 Page 48

100

←TC1 temp ←Setpoint

Page 53

7-2. Changing 5100V Recorder From Degrees F to Degrees C And Change TC Descriptor

Press “Menu” (bottom right of display).

Select “Config“. Select “Channels” from pull down

menu.

scrn32

For each Channel Number (1-6):

1. Select “Channel Number”.

2. Maximum expected temperature range reading: 1500 for °F typ. (1472 °F) = 800 for °C typ.

3. Range units can be changed between 5F and 5C.

4. Descriptor can be changed in “Descriptor” field, if desired.

Press “Apply”. Log out.

scrn33

OM-203 185 Page 49

Page 54

7-3. Restoring Recorder Configuration From A Floppy Disk

(For 5100 Digital Recorder)

Touch top left corner (Logged Out) or (User). Touch Blue text (pull down menu) next to User. Touch Engineer. Touch Password field. Touch Numeric. Touch 1, then 0, then Ok.

7-3-1. Load File

Insert digital recorder configuration disk into recorder.

Touch key in bottom right corner to open Root Menu.

Touch Operator. Touch Save/R. Touch Restore. Touch field next to File Name. Touch up folder. Touch \Floppy\ (Highlights yellow). Touch down folder. Touch the desired 5100 Config file (####.uhz). Touch Open.

7-3-2. Date Setup

1. Touch System.

2. Touch Locale.

3. Touch pull down next to Country.

4. Touch appropriate country.

5. Touch pull down next to Time Zone.

6. Touch appropriate time zone (i.e. CST Central). See “http://www.timeanddate.com” for additional information.

7. Set DST (Daylight Savings Time) if applicable. Place an “X” in the box next to “Use Summertime (DST)” to enable this option.

NOTE

8. Touch Apply.

OM-203 185 Page 50

Page 55

7-3-3. Time Setup

1. Touch System.

2. Touch Clock.

3. Adjust time, if necessary.

4. Touch Apply.

7-3-4. Login As User

1. Touch top left corner (Engineer).

2. Touch pull down next to User.

3. Touch User from pull down list.

7-3-5. Go To Home Screen

1. Touch key in bottom right corner to open Root Menu.

2. Touch Home.

OM-203 185 Page 51

Page 56

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Turn Off all power before maintaining.

3 Months

Replace

Cracked

Parts

6 Months

Blow Out

Vacuum

Inside

Replace

Unreadable

Labels

8-2. Troubleshooting

Trouble Remedy

IH/TS does not power up.

Display flashes 5.br

Display flashes1dHi Workpiece actual temperature is more than 25 degrees over the target temperature. Wait for workpiece

Be sure that power switch on rear of IH/TS is in the On position.

Check 115 volts ac at receptacle where IH/TS is plugged in.

Be sure that IH/TS is not plugged into a switched receptacle.

Check power source primary power for 3-phase, 400 or 460 volts ac (depending on model).

Replace building line fuse or reset circuit breaker.

For 5 kW PWHT cart, remove transformer cover on back of running gear, and check terminal strip jumpers to verify they are set in the correct position. For 25 kW PWHT system cart, remove transformer cover on back of running gear, and check for loose lead connections.

Thermocouple open, connect thermocouple.

Two pin thermocouple plugged into ground (copper) pin, reconnect to the two silver pins.

temperature to drop or follow the recovery procedure in Section 6-3-5.

Power source contactor turns On and Off at 25° over target temperature.

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

If display flashes no.io. Remove 2408 control from its housing by pressing locking tabs outward slightly on sides of control and pulling

OM-203 185 Page 52

Change Panel/Remote switch on power source to Remote position.

it to Exit YES, and the controller will reset automatically.

control forward. Look for add−on PC card in back of controller, and check that white connector is fully inserted into 2408 control. Reinstall 2408 control into housing being careful not to damage locking tabs on housing.

Page 57

Trouble Remedy

If display flashes no.io again, or if 0-10 V output card fails.

Output stops when green Run button is released.

Temperature readings go down instead of up.

Temperature readings do not rise. Check for a short between thermocouple wires.

Temperatue does not change in ramp segment.

Fault/Limit light is on.

Current Source fault.

2408 Controller displays dwell before 10 degree window is reached.

Remove 2408 control from its housing by pressing locking tabs outward slightly on sides of control and pulling control forward. Look for add−on PC card in back of controller, and remove PC card. Reinstall 2408 control into housing being careful not to damage locking tabs on housing. Disable output card function as follows: Goto ConF, IA ConF (Module 1 Config). See Section 8-5-4. 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.

Replace Hold button.

Check for reversed red (−) and yellow (+) leads in 2-pin thermocouple, and correct if necessary.

Change the ramp rate for that segment in the Program List.

Parameter Display will indicate either “Coolant Flow Error” or “PS Limit”.

“Coolant Flow Error” − ensure that cooler is plugged in and turned on.

For 25 kW system, ensure receptacle switch is on. Check coolant level in reservoir, and add coolant if necessary. Check filter on cooler and replace, if necessary. Verify that coolant “IN” and “OUT” hoses are connected to the correct fittings. Check alignment of center pins in plastic quick disconnect fittings. Be sure that coolant jumpers are connected properly.

“PS Limit” indicates the power source will run at less than full output.

Verify panel/remote switch on power source is in Remote position. Turn down dial on front panel of power source until light goes out or To obtain full output, adjust the coil to get more coupling into the part. Check set-up parameters. If Volts setting is greater than 650, add a turn to the heating coil.

Remove a turn from the heating coil.

Power/Volts equals Real Current, Real Current must be kept under 60 A.

Check that Hold Back setting is in Band, display will read Hb bAnd (see Section 8-5-3, Goto Ful, ProG LiSt).

Check that Hold Back Units equals 10 F, display will read Hb U 10 (see Section 8-5-3, Goto Ful, ProG LiSt).

Parameter display does not operate, but 2408 Temperature Controller and 5100V Recorder displays do operate.

2408 Temperature Controller display does not operate, but 5100V Recorder display does operate.

5100V Recorder does not turn on, but 2408 Temperature Controller does turn on.

Flow/Limit light does not illuminate when cooler is turned off.

Heat On light does not display when power source is supplying output.

Output does not start when Run button is pressed.

Pressing Power Source Select button on rear of IH/TS does not change selection.

5100V Recorder displays Channel Error.

See Section 8-3A.

See Section 8-3B.

See Section 8-3C.

See Section 8-3D.

See Section 8-3E.

See Section 8-3F.

See Section 8-3G.

See Section 8-3H.

OM-203 185 Page 53

Page 58

Trouble Remedy

2408 Temperature Controller reads greater than 5° F different than Channel 1 on 5100V Recorder.

2408 Temperature Controller readings fluctuate rather than remain stable.

5100V Recorder screen blinks when touched, but does not advance to next screen.

5100V Recorder does not recognize floppy disk.

See Section 8-3I.

Check and secure connections to the workpiece.

Screen calibration needs adjusting. Turn off IHTS power switch. Turn on IHTS power switch while touching screen, and continue to touch screen (about 45 seconds) until configuration display appears on the screen. Press “Touch Cal” or wait a few minutes for the Touch Cal display to appear on the screen. Use a pointed object (be careful not to damage screen), and touch each set of cross hairs to calibrate screen. When calibration is complete, turn IHTS power off and back on again.

Floppy disks do not work well in ambient temperatures greater than 104° F (40° C).

Clean floppy drive with a disk drive cleaner (available from a local computer reseller).

OM-203 185 Page 54

Page 59

8-3. Diagnostic Procedures For IH/TS

A. Parameter Display Does Not Operate, But 2408 Temperature Controller And 5100V Recorder Displays Do

Operate.

Turn on power source. Remove 14-pin control cable from power source and IH/TS. Check for bent pins in 14-pin control cable and on IH/TS receptacle. Check for +24 volts dc between pins A and D at power source receptacle. If +24 volts dc is not present, consult power source Owner’s Manual for troubleshooting. Connect 14-pin control cable to power source. Check for +24 volts dc between pins A and D at IH/TS end of cable. If +24 volts dc is not present, replace 14-pin control cable. Connect 14-pin control cable to IH/TS. Unplug IH/TS 115 volts ac power cord. Remove IH/TS wrapper. Check that plug PLG3 is fully inserted into receptacle RC3 on circuit board PC1. Check for loose wires in 14-pin receptacle and plug PLG3. Check for +24 volts dc between pins 7 (−) and 15 (+) at plug PLG3 and receptacle RC3. If +24 volts dc is not present, check wiring from plug PLG3 to receptacle RC10. Check that display ribbon cable is fully connected to receptacle RC1 on circuit board PC1 (grey foil on pin 1). Check solder joints of ribbon cable to display. Disconnect ribbon cable from display at receptacle RC1. Check for +5 volts dc between pins 1 (−) and 2 (+) at receptacle RC1, and proceed as follows: If +5 volts dc is present, replace the display; if 5 volts dc is not present, replace circuit board PC1. Reconnect IH/TS 115 volts ac power cord.

B. 2408 Temperature Controller Display Does Not Operate, But 5100V Recorder Display Does Operate

Remove and reseat 2408 controller module, make sure that locking tabs are in place. Remove IH/TS wrapper. Check for 115 volts ac between L and N at terminal strip on rear of controller module. If 115 volts ac is present, replace 2408 Temperature Controller; if 115 volts ac is not present, check wiring.

C. 5100V Recorder Does Not Turn On, But 2408 Temperature Controller Does Turn On

Place IH/TS power switch in the Off position. Open floppy drive door. Place IH/TS power switch in the On position. Check for floppy drive light illumination. If drive light does not illuminate, proceed as follows: Remove IH/TS wrapper.

OM-203 185 Page 55

Page 60

Check for 115 volts ac at plug on rear of recorder and reseat plug.

If 115 volts ac is not present, check wiring between plug PLG4, receptacle RC4, and power switch. If 115 volts ac is present at plug on rear of recorder, check that green LED is illuminated by viewing through louvers

on side of recorder. A green LED should be visible through the louvers on the side of the recorder. If green LED is not illuminated, replace recorder.

If drive does illuminate, replace the recorder.

D. Flow/Limit Light Does Not Illuminate When Cooler Is Turned Off

Check that cooler is plugged into switched receptacle and switch is in the Off position. Unplug cooler power cord from receptacle. Disconnect power output/extension cable from power source. Press green Run button, and check if Fault/Limit light illuminates.

If light did not illuminate, check if power source displays Under Frequency Fault.

If power source does not display fault, consult power source Owner’s Manual for troubleshooting.

If power source does display fault, check parameter display for error message.

If error message appears on parameter display, proceed as follows:

Remove Fault/Limit amber lense and bulb. Check for 115 volts ac at light socket. If 115 volts ac is present, replace Fault/Limit bulb. If 115 volts ac is not present, proceed as follows:

Remove IH/TS wrapper. Check for 115 volts ac between pin 13 at receptacle RC3 and neutral (switch S1-1, lead 2). If 115 volts ac is present, check wiring for Fault/Limit light PL-2. If 115 volts ac is not present, check for 115 volts ac between pin 14 at receptacle RC3 and neutral (switch

S1-1, lead 2).

If 115 volts ac is present, replace circuit board PC1.

If 115 volts ac is not present, check wiring from pin 14 at receptacle RC3. If no error message appears on the parameter display, proceed as follows: Unplug IH/TS 115 volts ac power cord.

Remove IH/TS wrapper. Check for an open circuit at RC3 between pins 17 and 18. If circuit is open, replace circuit board PC1. If circuit is not open, consult power source Owner’s Manual for troubleshooting.

Reconnect IH/TS 115 volts ac power cord.

If light illuminates, disconnect Coolant In (red) fitting from IH/TS. Spray silicone lubricant into fitting. Insert a long narrow screwdriver into fitting and actuate flow switch plunger several times. Remove IH/TS wrapper. Disconnect flow switch leads.

OM-203 185 Page 56

Page 61

Check Flow/Limit light for illumination. If light does not illuminate, replace circuit board PC1. If light does illuminate, proceed as follows:

Check switch leads for continuity when switch is activated. Check switch leads for open circuit when switch is deactivated. If continuity is always present at switch leads, replace flow switch.

E. Heat On Light Does Not Display When Power Source Is Supplying Output

Remove IH/TS wrapper. Check for 24 volts dc at LED (this LED is polarity sensitive, red mark on plastic lense is + side).

If 24 volts dc is present, replace LED. If 24 volts dc is not present, another source rather than the IH/TS is energizing the power source. Check for a short

circuit between pins A and B in the 14-pin control cable.

F. Output Does Not Start When Run Button Is Pressed

Check for 5.br on 2408 Temperature Controller display. Fully press and release Stop and Hold buttons, then try pressing the Run button. If actual temperature is higher than target temperature, see recovery procedure in Section 6-3-5. Remove 14-pin control cable from IH/TS. Jumper pins A and B in plug on 14-pin cable. If no output is present, proceed as follows:

Remove 14-pin control cable from power source. Jumper pins A and B at power source receptacle.

If no output is present, consult power source Owner’s Manual for troubleshooting. If output is present, replace 14-pin control cable.

If output is present, proceed as follows:

Unplug IH/TS 115 volts ac power cord. Check Run, Hold and Stop switches for operation.

G. Pressing Power Source Select Button On Rear Of IH/TS Does Not Change Selection

Remove IH/TS wrapper. Jumper across leads at Power Source Select button (dry circuit). If selection changes, replace switch. If selection does not change, proceed as follows:

Jumper between pins 1 and 2 at RC2 on circuit board PC1. If selection changes, replace wiring to the switch. If selection does not change, replace circuit board PC1.

H. 5100V Recorder Displays Channel Error

Recorder will not operate below 32° F, allow 15-30 minutes for warm up or move recorder to a warmer location. Remove IH/TS wrapper. Remove red cover on rear of recorder. Check that terminal strip is secure on rear of recorder.

OM-203 185 Page 57

Page 62

Ribbon cable may be disconnected inside of recorder after prior maintenance, reconnect ribbon cable. If above procedures do not clear the error message, replace recorder.

I. 2408 Temperature Controller Reads Greater Than 55 F Different Than Channel 1 On 5100V Recorder

Remove IH/TS wrapper. Check that red (−) and yellow (+) leads are secure between clamp and copper pad on rear of temperature controller. Connect a thermocouple to TC1 input. If temperature controller drifts while power source is off, replace temperature controller. If recorder readings drift while power source is off, replace recorder. If power source output varies (audible frequency change) while attempting to maintain temperature, replace

temperature controller. If recorder readings drift while temperature controller is maintaining temperature, replace recorder.

8-4. Resetting All RAM Variables In The Event Of Display Errors

Re l ease But t on

Press

Power Sour ce Sel ec t

To Reset

RESETT ING MEMORY

MEMOR Y RE SE T

. This procedure will reset all

stored variables in RAM memory including scaling, programs, counters, and security code.

Before turning on power at the power source, press and hold Power Source Select button.

Turn on power at power source. 1 Release Button Display When “Release Button” appears on

the display, release the button. 2 Press Power Source Select

To Reset Display

After the display changes to “Press Power Source Select To Reset”, press Power Source Select button to reset all stored variables in RAM.

3 RESETTING MEMORY

Display

“RESETTING MEMORY” will appear on the display automatically during the RAM memory reset operation.

4 “MEMORY RESET” Display “MEMORY RESET” will appear on

the display after completion of RAM memory reset.

The IH/TS will restart with factory set default parameters in RAM memory.

OM-203 185 Page 58

Page 63

8-5. Factory Set Parameters

If it becomes necessary to return to factory settings, the following sections list factory settings for the 2408 controller. All settings can be accessed through the Goto screen. To access the Goto screen, proceed as follows:

Press Page to

Press Scroll

After selecting the desired Goto screen, press the scroll button to display the menu. Press the page button to move from left to right through the columns; press the scroll button to move down the column;

press the up or down arrow to change parameter settings, if necessary.

AccS LiSt

codE

Wait 2 sec.

codE PASS

Goto OPEr

toB

Goto ConF

toB

Goto Edit

toB

Goto Ful

8-5-1. Controller Version Number

When the controller is first turned on, the version number will display breifly, and appear as shown.

Controller configuration parameters vary based upon version number. See appropriate

2400

Version Number

(V4.09 Effective w/Serial No. LC089021)

Section for the corresponding version number.

V4.09

OM-203 185 Page 59

Page 64

8-5-2. 2408 Controller Edit Parameters

. Refer to Section 8-5 for additional navigation instructions.

Goto

Edit

Navigation

Page Across

Home Run Programmer Alarm Autotune PID Setpoint Input Output Information Access

List List List List List List List List List List List

74 run ProG AL Atun Pid SP iP oP inFo ACCS

rEAD rEAd rEAd HIdE HIdE HIdE HIdE HIdE HIdE HIdE LiSt

74 StAt Hb

% f ALtr HIdE

Scroll Down

OP PSP Hb U

ALtr ALtr HIdE

SP CYC rmP.U

ALtr HIdE HIdE

w.SP SEG dwL.U

ALtr ALtr HIdE

m−A StyP CYC.n

HIdE ALtr HIdE

C.id SEG.t

HIdE ALtr

tGt

ALtr

rAtE

ALtr

PrG.t

ALtr

FASt

ALtr

SEG.d

ALtr

OM-203 185 Page 60

Page 65

8-5-3. 2408 Controller Full Parameters (Prior To Version V4.09)

Access

List

ACCS

LiSt

varies

OFF

varies

1.0 varies

varies

varies Auto varies

varies

. Refer to Section 8-5 for additional navigation instructions.

Goto

FuLL

74 run ProG AL Atun Pid SP iP oP inFo

Home Run Programmer Alarm Autotune PID Setpoint Input Output Information

List List List List List List List List List List

100 LiSt LiSt LiSt LiSt LiSt LiSt LiSt LiSt LiSt

1 0.0 1450

CYC.n rES SP H Li.1 ont.H LoG.t

no 10 2 O FF 14 100 0 100.0

74 StAt Hb 1dHi tunE Set SSEL FiLt OP.Lo diSP

OP FAST Hb U HY 1 drA Pb SP 1 OFS.1 OP.Hi LoG.L

m−A SEG.d rmP.U Lb t drA.t ti SP 2 mU.1 Oprr LoG.H

varies

% f O FF bAnd 25 OFF Pid.1 SP1 3.0 0.0 Std

Auto Yes Hour OFF 10 49 400

0 Hour no mAn O FF 0

C.id dwL.U diAG Adc td SP L CJC.1 CYC.H LoG.A

1 Auto 0 iP.1 0.0 0

SEG.n Hcb SP2.L PU.sL End.P LoG.u

tYpe dur Lcb SP2.H Sb.OP rES.L

step 1.0 Auto 1450 0.0 no

tgt seg.n Pb2 SPrr mCt

2 rmp.r 150 OFF 100.0

600 4 50 OFF

seg.n tYpe ti2 Hb.ty w.OP

tYpe tgt td2 P OP

tgt rate rES.2 I OP

1250 600.0 0.0

rmp.r 600 50

rate Seg.n Hcb2 d OP

3 end Auto

600.0 5 Auto 0

seg.n tYpe Lcb2

tYpe end.t

dwel s Op

Navigation

Page Across

Scroll Down

OM-203 185 Page 61

Page 66

8-5-4. 2408 Controller Configure Parameters (Prior To Version V4.09)

. Refer to Section 8-5 for additional navigation instructions.

Goto

conF

SP AL PROG LA Lb AA HA JA 1A 2A 3A CAL PASS Exit

Process Logical Logical Alarm

Navigation

OM-203 185 Page 62

Page Across

Instrument Value Input Setpoint Alarms Programmer Inputs A Inputs B relay Comms 1 Comms 2 Module 1 Module 2 Module 3 Calibration Password

Config Config Config Config Config Config Config Config Config Config Config Config Config Config Config Config

inSt PV

ConF ConF ConF ConF Conf ConF ConF ConF ConF Conf Conf ConF ConF ConF ConF ConF no

Act dEc.P CJC rm.tr Ltch HbAc Func Func Func Func Func Func Func Func UCAL cnF.P

Pid % F k.tc 2 dHi 1 LoG.I LoG.I rELy none none dc.OP none none none 1

CtrL unit inPt nSP AL 1 PtyP id id id id id id id id rcAL ACC.P

Scroll Down

rEv nnnn Auto OFF no ProG r−H rES diG none none HEAT none none no 2

Lin 0 Auto OFF no rSEt n or 0 0

Sec 1450 OFF OFF to.PV YES 100 1000

Err Pmin n o no voLt 0.0

COOL rnG.L imP m.tr bLoc Pwr.F SEnS VAL.L Pt1.L

ti.td rnG.H Pr.tr AL 2 Srvo 1dHi VAL.H Pt1.H

dtyP rmP.U Ltch AL 2 unit OF1.L

m−A rmt bLoc AL 3 Out.L OF1.H

diSA none no no 0.0 0.0

r−h AL 3 AL 4 Out.H

diSA OFF no 10.0

PwrF Ltch mAn dc.F

OFF no no no

Fwd.t bLoc Sbr rmt.F

no OFF no no

nonE no no n o

Pd.tr AL 4 SPAn iP1.F

Sbr.t Ltch Lbr nw.AL

no no no YES

Sb.OP no no no

FOP bLoc Ld.F End

bcd tunE Sync

none no no

Gsch

Page 67

8-5-5. 2408 Controller Full Parameters (Effective w/Version V4.09)

Access

List

ACCS

LiSt

Goto

FuLL

varies

OFF

varies

1.0 varies

varies

varies Auto varies

w.OP

100.0

. Refer to Section 8-5 for additional navigation instructions.

Navigation

Page Across

74 run ProG AL Atun Pid SP iP oP inFo

Home Run Programmer Alarm Autotune PID Setpoint Input Output Information

List List List List List List List List List List

74 StAt Hb 1dHi tunE Set SSEL FiLt OP.Lo diSP

100 LiSt LiSt LiSt LiSt LiSt LiSt LiSt LiSt LiSt

% f O FF bAnd 25 OFF Pid.1 SP1 3.0 0.0 Std

Scroll Down

OP FAST Hb U HY 1 drA Pb SP 1 OFS.1 OP.Hi LoG.L

no 10 2 O FF 14 100 0 100.0

varies

1 0.0 1450

CYC.n rES SP H Li.1 ont.H LoG.t

Auto Yes Hour OFF 10 49 400

0 Hour no mAn O FF 0

C.id dwL.U diAG Adc td SP L CJC.1 CYC.H LoG.A

m−A SEG.d rmP.U Lb t drA.t ti SP 2 mU.1 Oprr LoG.H

1 Auto 0 iP.1 0.0 0

SEG.n Hcb SP2.L PU.sL End.P LoG.u

tYpe dur Lcb SP2.H Sb.OP rES.L

step 1.0 Auto 1450 0.0 no

tgt seg.n Pb2 SPrr

2 rmp.r 150 OFF

600 4 50 OFF

seg.n tYpe ti2 Hb.ty

tYpe tgt td2

rmp.r 600 50

tgt rate rES.2

1250 600.0 0.0

rate Seg.n Hcb2

600.0 5 Auto

seg.n tYpe Lcb2

3 end Auto

tYpe end.t

dwel s Op

OM-203 185 Page 63

Page 68

8-5-6. 2408 Controller Configure Parameters (Effective w/Version V4.09)

SSr.F

Ct.Sh

Ct.OP

tunE

. Refer to Section 8-5 for additional navigation instructions.

Goto

conF

Process Logical Logical Alarm

SP AL PROG LA Lb AA HA JA 1A 2A 3A CAL PASS Exit

no no

Htr.F Sync

no no no

no no YES

OFF no no

AL 4 SPAn iP1.F

Ltch Lbr nw.AL

bLoc Ld.F End

EnAb

Sbr.t

Navigation

OM-203 185 Page 64

Page Across

Instrument Value Input Setpoint Alarms Programmer Inputs A Inputs B relay Comms 1 Comms 2 Module 1 Module 2 Module 3 Calibration Password

Config Config Config Config Config Config Config Config Config Config Config Config Config Config Config Config

inSt PV

ConF ConF ConF ConF Conf ConF ConF ConF ConF Conf Conf ConF ConF ConF ConF ConF no

Act dEc.P CJC rm.tr Ltch HbAc Func Func Func Func Func Func Func Func UCAL cnF.P

Pid % f k.tc 2 dHi 1 LoG.I LoG.I rELy none none dc.OP none none none 1

CtrL unit inPt nSP AL 1 PtyP id id id id id id id id rcAL ACC.P

Scroll Down

rEv nnnn Auto OFF no ProG r−H rES diG none none HEAT none none no 2

Lin 0 Auto OFF no rSEt n or 0 0

Sec 1450 OFF OFF to.PV YES 100 1000

Err Pmin n o no voLt 0.0

COOL rnG.L imP m.tr bLoc Pwr.F SEnS VAL.L Pt1.L

ti.td rnG.H Pr.tr AL 2 Srvo 1dHi VAL.H Pt1.H

dtyP rmP.U Ltch AL 2 unit OF1.L

m−A rmt bLoc AL 3 Out.L OF1.H

diSA none no no 0.0 0.0

r−h AL 3 AL 4 Out.H

diSA OFF no 10.0

PwrF Ltch mAn dc.F

OFF no no no

Fwd.t bLoc Sbr rmt.F

nonE no no n o

Sbr.t

Sb.OP

FOP

bcd

none

Gsch

100

LCiHi

Page 69

8-6. Calibration Certification Procedure

The following items are required for verifying calibration:

1. Fluke-714 Thermocouple Calibrator this can be obtained from: http://www.fluke.com/products/home.asp?SID=13&AGID=9&PID=1707 specify primary standard certification when ordering.

2. Type-K Mini Connector (Fluke #80CK-M) Or Equivalent this can be obtained from: http://thermo-electric-direct.com.control.interliant.com/ Miniature_Quick-Coupling_Thermocouple_Connectors10630.html

3. Type-K 2-Pin Male Connector this can be obtained from: http://thermo-electric-direct.com.control.interliant.com/ Standard_Quick-Coupling_Thermocouple_Connectors7886.html

4. Calibration Labels − Part No. QCC306BU BLUE these can be obtained from: http://www.q-cees.com/itemdetail.asp?part=206

5. A length of type-K thermocouple wire connected between the type-K mini connector and type-K 2-pin connector.

1. Fluke-714 Thermocouple Calibrator

2. Type-K Mini Connector

3. Type-K 2-Pin Male Connector

4. Calibration Labels

Perform the procedure as follows:

1. Press the down arrow on bottom left of digital recorder to display numeric page.

. Allow readings to stabilize before recording.

2. Set Fluke-714 TC Calibrator to 382.0 degrees F. a. Move TC Calibrator from TC1 through TC6 in sequence recording each value read onto the Certificate of

Calibration.

b. Verify readings are within ±3 degrees F of TC Calibrator.

. If readings are beyond the +3degrees F, the instrument will need to be returned to Eurotherm for repair.

Phone: 703-669-1316 E-mail: repairs@eurotherm.com web page: www.eurotherm3.com/repairs.htm

c. Repeat at 882.0 degrees F and at 1382.0 degrees F

3. Save a copy of the Certificate using the IH/TS serial no. and date as the file name, i.e. “LB056241 062501” for

June 25, 2001.

4. Print a copy of the certificate to send with the IH/TS.

5. Complete calibration sticker and apply to IH/TS front panel below recorder.

I.D. No. (IH/TS serial no.) By (your initials) Date (today’s date) Due (date 1 year from today)

OM-203 185 Page 65

Page 70

SECTION 9 − ELECTRICAL DIAGRAMS

OM-203 185 Page 66

215 588-A

Figure 9-1. Circuit Diagram For IH/TS

Page 71

SECTION 10 − PARTS LIST

Ref. 803 005-A

Figure 10-1. Complete Assembly

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. Complete Assembly

1 203 262 NAMEPLATE, w/o recorder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 204 366 NAMEPLATE, w/recorder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 147 582 LENS, clear anti glare 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 174 446 GASKET, meter lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 156 005 TUBING, nyl 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 203 182 LCD, w/ribbon cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 204 039 MOUNT, nprn 1/8 din controller 55 durometer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 081 543 FTG, coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 186 162 RELAY, encl 120VAC DPDT 5A/120VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 203 181 CIRCUIT CARD ASSY, pendant control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 164 899 HOUSING PLUG PINS & SKTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 169 240 HOUSING PLUG PINS & SKTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 072 253 STUD, connection single 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 115 090 HOUSING PLUG & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 088 731 BUSHING, snap-in nyl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 113 333 SWITCH, pb mc no SPST 1A 115 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 203 089 PANEL, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 147 876 LABEL, warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 +194 029 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 134 201 STANDOFF 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 115 094 HOUSING PLUG & SKTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 158 506 SWITCH, rocker DPDT 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-203 185 Page 67

Quantity

Page 72

Dia.

Mkgs.

Part

No.

Description

Figure 10-1. Complete Assembly (Continued)

22 198 893 RECEPTACLE, thermocouple 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 209 948 BRACKET, mtg receptacle RJ45 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 175 282 COVER, receptacle weatherproof duplex rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 203 975 CAPACITOR ASSY 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 198 885 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 204 702 CORE, toroidal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 204 703 CORE, toroidal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 203 264 NAMEPLATE,rear w/o recorder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 204 367 NAMEPLATE, rear w/recorder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 152 492 RCPT W/PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 204 227 BRACKET, mtg IH/TS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 204 040 MOUNT, nprn 100mm recorder 55 durometer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 214 532 CABLE ASSY, interconnecting RJ45 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 194 067 CASE SECTION, front/bottom/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 202 602 SWITCH, flow w/fittings 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 194 068 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 194 920 RECORDER, temperature, digital 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 212 719 KIT, switch replacement for 203 137 (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 137 SWITCH, pb mc DPST NC/NO 1A 115VAC red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*210 369 BOOT, switch pushbutton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 212 718 KIT, switch replacement for 203 136 (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 136 SWITCH, pb mc nc SPST 1A 115VAC black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*210 369 BOOT, switch pushbutton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 212 717 KIT, switch replacement for 203 135 (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 135 SWITCH, pb mc nc SPST 1A 115VAC green 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*210 369 BOOT, switch pushbutton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 027 631 HOUSING, light 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

027 629 BULB, incand 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 246 LENS, light 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 197 062 LED, blue 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 202 200 TEMPERATURE CONTROLLER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 457 CORD, power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *If replacing a boot only onto an existing switch, apply a silicone spray on both boot and switch to prevent moisture

buildup inside boot and ease installation.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-203 185 Page 68

Page 73

Notes

Page 74

Notes

Page 75

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

Effective January 1, 2005

(Equipment with a serial number preface of “LF” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig * Maxstar 150 * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

Spoolguns) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources and Coolers * Water Coolant Systems (Non-Integrated) * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Maxstar 85, 140 * Spot Welders * Load Banks * Arc Stud Power Sources & Arc Stud Guns * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue® for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets * APT & SAF Model Plasma Cutting Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate Spoolguns * Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 1/05

Page 76

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Miller Electric IH, TS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual