Miller Electric ProHeat 35 manual Symbol Usage, Induction Heating Hazards, Electric Shock can kill

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

ihom _2007−04

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards.

1-2. Induction Heating Hazards

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.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The power circuit and output bus bars or connections are electrically live whenever the output is on. The input power circuit and machine

internal circuits are also live when power is on. Incorrectly installed or improperly grounded equipment is a hazard.

DDo not touch live electrical parts.

DEnclose any connecting bus bars and coolant fittings to prevent unintentional contact.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

DAdditional 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 ac- cidental contact with the workpiece or ground. For these conditions, see ANSI Z49.1 listed in Safety Standards. And, do not work alone!

DDisconnect input power before installing or servicing this equip- ment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

DUse only nonconductive coolant hoses with a minimum length of 18 inches (457 mm) to provide isolation.

DProperly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

DAlways 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.

DWhen making input connections, attach proper grounding conductor first − double-check connections.

DKeep cords dry, free of oil and grease, and protected from hot metal and sparks.

DFrequently inspect input power cord for damage or bare wiring − re- place cord immediately if damaged − bare wiring can kill.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DDo not touch power circuit if you are in contact with the work, ground, or another power circuit from a different machine.

DUse only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

SIGNIFICANT DC VOLTAGE exists in inverter-type power sources after removal of input power.

DTurn 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.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation to re- move fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for adhesives, fluxes, metals, consumables, coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson near- by. Fumes and gases from heating can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

DDo not heat in locations near degreasing, cleaning, or spraying oper- ations. The heat can react with vapors to form highly toxic and irritating gases.

DDo 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 air- supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if overheated. See coating MSDS for temperature information.

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Contents Description OM-222 166K 2007−11 ProcessesFile Induction Heating From Miller to You Table of Contents EMF Information − MaintenanceRoutine Maintenance Blowing Out Inside Of Unit Limit Conditions Limit Condition Codes Fault ConditionsStandards DirectivesDecstat1/07 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 blesserPrincipales normes de sécurité Information EMF Proposition californienne 65 AvertissementsEn 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 Socket Information Remote 14 Receptacle RC14 Information and ConnectionsSocket 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 NumberTypical 5-Segment Custom Program Manual ControlSoak 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 CoolerReal-Time Operation Must be running to enter Hold modeProgram 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 Condition Codes Fault ConditionsFault Condition Additional Information Off Cable1 LQD DIAG1 OutI1 Cable2 LQD OutI2 ClntFR 0.75 GPM System Diagnostic ScreensClrSts Flowing VBus Therm1Therm2 Therm3Removing Wrapper and Measuring Input Capacitor Voltage Turn Off welding power source, and disconnect input powerTools 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 Your distributor also gives ServiceSupport 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
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