Miller Electric Guide to Using the Thermocouple Attachment Unit with Miller ProHeat 35

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4-15. Attaching Welded Thermocouples

.Do NOT weld thermocouples while connected to power source.

1.Attach thermocouples using a portable Thermocouple Attachment Unit (TAU). This unit spot welds thermocouple wire directly to the workpiece. This method of thermocouple attachment ensures accurate temperature measurement.

2.Clean (file or grind) any loose scale or rust from the workpiece at the places where the wires will be attached.

3.Clean the location for the lead magnet to minimize resistance. Place the magnet as near to the thermocouple positions as possible.

4.Strip 1/4 inch of insulation from the thermocouple wires.

5.Set the output variable control of the TAU to about eighty percent (80%).

6.Grasp one of the stripped wires with the tip of the jaws of the application pliers.

.Don’t touch both wires of the thermocouple to the pliers at the same time when energizing the Thermocouple Attachment Unit. This will cause the thermocouple wire to fuse to the pliers, rather than the workpiece.

7.Press the end of the wire to the workpiece at ninety degrees to the surface, and maintain a firm pressure. Make sure the Thermocouple Attach- ment Unit is charged and wait for the ready light to glow.

8.Press discharge button, and the wire should weld to the workpiece. There will be a sharp crack and a slight arc flash.

9.Repeat the process with the other wire, placing it approximately 1/4 inch away from the first wire. Attach a spare thermocouple, and support both thermocouples approximately 18 inches back from the connection with a band or fiber tape.

10.Carefully bend the wire over at right angles. This brings the thermocouple wires out along or parallel to the workpiece. It also tests the strength of the weld. If the weld shows signs of breaking, remove the wire, restrip the end, and repeat the process.

Strap Or Tape

Thermocouple

Wires

804 322-A

OM-222 166 Page 21

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Contents OM-222 166K 2007−11 Processes DescriptionFile Induction Heating From Miller to You Table of Contents EMF Information − MaintenanceRoutine Maintenance Blowing Out Inside Of Unit Limit Conditions Limit Condition Codes Fault ConditionsDirectives StandardsDecstat1/07 Page Fumes and Gases can be hazardous Symbol UsageInduction Heating Hazards Electric Shock can killCalifornia Proposition 65 Warnings About Implanted Medical Devices Principal Safety Standards EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UNE Décharge Électrique peut entraîner la mortDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLE Chauffage PAR Induction peut provoquer des brûlures LA Chute DE L’APPAREIL peut blesserProposition californienne 65 Avertissements Principales normes de sécurité Information EMFEn ce qui concerne les implants médicaux − Definitions Kill Shown by the symbolsPower before working on Are possible hazards asWeee Label For Products Sold Within The EU Rating Label For CE ProductsI1max − InstallationSymbols And Definitions SpecificationsMovement Location And Airflow Do not move or operate unit where it could tipSelecting a Location TippingMin Grounding Conductor Size In AWG Electrical Service GuidePhase Input Voltage 50 Hz ThreeGND/PE Earth Ground Connecting 3-Phase Input Power For 460/575 Volt ModelsWelding Power Source Input Power Connections Disconnect Device Input Power ConnectionsConnecting 3-Phase Input Power For 400/460 Volt Models Power Source Output Connections Remote 14 Receptacle RC14 Information and Connections Remote 14 Socket InformationSocket Socket Information Unused Temperature Recorder Socket InformationSignal Common Socket No Socket InformationWorkpiece Use handle to place magnet on the workpiece Secondary Insulation ProtectionReceptacles Plug Handle MagnetLocating Thermocouples Volt AC Duplex Receptacle And Supplementary ProtectorOther end is fitted with a 2-pin type K connector Attaching Welded Thermocouples Do not weld thermocouples while connected to power sourcePlacing Temperature Probe Using Contact ThermocouplesControls − Components and ControlsSystem Description − Setup and OperationSafety Equipment Power Source/System SetupOM-222 166 Programming Temperature-Based ControlMode....... Preheat Control TC Temperature Soak Time Decrease button to change the value to the desired settingPwht Post-Weld Heat Treat Bake-OutCustom Program Soak Parameters600 Custom ProgramEnd Type.......StepNumber OM-222 166 Ramp Temperature 600 Ramp Rate 600 /HrEnd Function SoakSoak Function NumberManual Control Typical 5-Segment Custom ProgramSoak at 1250 degrees F for a period Preheat, Bake-Out And Pwht Run Status Screen Temperature Based ControlRun Status TC5 Target Temp −−−− TC6 Countdown.. −−−−−−Cooler cannot be turned off while output is on Power TC5 Current TC6 Voltage Frequency KHzParameters CoolerMust be running to enter Hold mode Real-Time OperationProgram run is initiated, the Run Button. a change of program parameters Liquid Cooled Output System Operating CharacteristicsPower Source Output Characteristics Air Cooled OutputBefore maintaining − MaintenanceRoutine Maintenance Disconnect powerServicing Hazards − Safety Precautions for ServicingCalifornia Proposition 65 Warnings Operator Interface Indicators − Diagnostics & TroubleshootingLimit Condition Additional Information Limit ConditionsLimit Condition Codes Run StatusFault Conditions Fault Condition CodesFault Condition Additional Information System Diagnostic Screens Off Cable1 LQD DIAG1 OutI1 Cable2 LQD OutI2 ClntFR 0.75 GPMClrSts Flowing VBus Therm1Therm2 Therm3Turn Off welding power source, and disconnect input power Removing Wrapper and Measuring Input Capacitor VoltageTools Needed 16, 3/8 Blowing Out Inside Of Unit Material Thickness Reference ChartCircuit Diagram − Electrical Diagram218 057-G See Figure 11-313 11-2 − Parts ListFront Panel Rear Panel Base w/Components Top Windtunnel Capacitor Assembly Right Windtunnel 229 Right Windtunnel 400 V Model Only 208 Left Windtunnel PLG14 10. Hermaphroditic Blank Plug Assy SOCKET/WRENCH Selection Table Standard Metric OM-222 166 Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact