FAQs - MillerWelds

FAQs

Auto-Line

What is dirty power?

Fabricators, contractors and manufacturers often fight weld quality and maintenance problems that result from primary voltage fluctuations, or "dirty power." Dirty power is the result of unreliable primary power - large motors starting on the same primary power line, utility brownouts or spikes, and generators that do not regulate auxiliary power voltage.

How does dirty power affect weld quality?

A power surge or dip can cause your arc to flicker and your inverters to shut down for self protection. In some cases, you might not even know you experienced dirty power until the QA/QC department rejects your weld because it doesn't pass inspection.

What can I do to protect my work from dirty power?

Miller has developed its exclusive technology that frees operators from primary power limitations and allows uninterrupted production. Auto-Line is featured in Miller's Axcess Series of multi-MIG inverters; TIG inverters such as the Maxstar and Dynasty; multi-process inverters such as the XMT; and plasma cutters such as the Spectrum.

How does Auto-Line work?

Auto-Line technology uses what's known as "boost converter." This circuit boosts primary input power - from 190 through 630V or anywhere in between - to a higher voltage. This voltage then charges a capacitor, which is a device used to store and quickly discharge energy. Power for the actual inverter section of the welder comes from this capacitor. The inverter, therefore, has sufficient power as long as the primary power remains within a +37/-59 percent of the nominal 460V power. In short, it's like drawing water from a well that's always full.

What does Auto-Line do for weld quality?

Auto-Line ensures that you always draw welding or cutting power from a regulated, stable voltage source within the machine, which lets you ride effortlessly through dirty power. Auto-Line gives you a rock-steady arc, "on spec" welding parameters and equipment with an incredibly dynamic, link-free operating range.

What is the difference between Auto-Line and Auto-Link?

They're both examples of great technology from Miller. Auto-Line automatically and continuously adjusts for voltage surges and drops, providing a constant, steady arc and ensuring quality welds. Auto-Line does this regardless of input voltage, provided it is within the operating range of the equipment being used. Auto-Link "links" power, switching transistors for either 230 or 460V primary power only.

How do I know if an Auto-Line equipped inverter fits my needs?

Auto-Line is for anybody who can't afford re-work. And Auto-Line also gives you the flexibility to use the same machine in the shop and in the field because it smoothes out power fluctuations anywhere.

Buying a Plasma cutter

What is Air Plasma?

Plasma arc cutting is a process where an open arc, much like in TIG welding, can be constricted by passing through a small nozzle, or orifice, from the electrode to the work-piece. The gas used, typically air, combines with an electrical current to create a high temperature plasma arc. When placed in contact with an electrically conductive material, the arc passes through the metal, melting a thin area. The force of the arc pushes the molten metal through the work-piece and severs the metal.

What types of metal and applications can be used with a Plasma cutter?

Plasma will cut any metal that is electrically conductive including steel, aluminum, copper, and stainless steel. Keep in mind that your cut will be de-rated a little with the softer metals like aluminum, copper, and stainless. Rating refers to the thickness a plasma cutter can cut at a rate of 10 Inches Per Minute.

Is Plasma cutting a good tool for restoring cars?

Excellent!! The Miller Spectrum 375 X-TREME is perfect for auto work. It has both a 3/8" rated cut and will sever 1/2". That cut rating will cover anything on a car.

It can also plug into 110 or 220V and will give you the same cut off of either input.

The Spectrum 375 X-TREME is portable, weighing 18 lbs. 

What is nice about plasma is when you’re doing body-work you do not have to worry about warping or burning the paint. With plasma, the arc is so hot and tight the heat does not have time to spread out and effect the metal. Plasma is much faster and cleaner than anything else you could use (hacksaw, grinding wheel, etc.)

Is there a lot of skill involved with Plasma cutting?

No. Depending on what you are cutting and a steady hand there is not a lot of training involved to operate a Plasma cutter. The torch should remain at a 90-degree angle and depending on the machine you can keep a standoff or drag either the tip or the drag shield on the metal.

As far as controls on the machine there are only two, which include the on/off switch and the amperage control. The on/off speaks for itself and the amperage is only going to change when you want to cut thicker material, but most operators will leave the amperage switch on full output for all thickness of metal.

What are the necessary air requirements?

Compressed air is the most popular gas used for plasma cutting. You can use an air compressor or a bottle of compressed air. The CFM (Cubic Foot per Minute) is important because that is the amount of air that will be distributed per minute and will keep your Plasma machine running consistently. The PSI (Pounds per Square Inch) is the actual air pressure required to operate the machine. All machines need different PSI and CFM. For instance while the Spectrum 375 X-TREME requires 5 CFM at 90 PSI.

The other gas used is nitrogen, but the only advantages to using it are when cutting stainless steel. You will get a cleaner cut but the cut thickness will be diminished a little. With some exotic metals a gas mixture may be needed.

You will also want to have dry air when operating a plasma cutter. Miller offers a couple of Dryer/Filters that are designed to keep the air dry and clean. Dry air is important because if there is moisture in the line it will travel with the air and exit the end of the torch. This is not necessarily dangerous but will shorten the life of your consumables because the arc will follow the moisture in all directions and erode the tip prematurely.

What is consumed on a Plasma cutter?

There are two parts that will be used up in the torch. The first part is the tip. The tip has a perfectly round hole in the end that will become oblong over time. As it becomes oblong the arc will go to the to the other side and wear the tip even more. At this point it is time to change the tip.

The second part is the electrode. It is located under and inside the tip. There is a rare piece of metal called Hafnium in the tip of the electrodes that breaks off every time the arc is started. When the Hafnium is depleted there will be a 1/16" deep, and round crater in the tip of the electrode. At this point it is time to change the electrode.

Keep in mind that you will still get an arc and will be able to cut, but at a diminished thickness. By continuing to cut with depleted parts you will run the risk of ruining other parts of the torch that should normally last for a long time. Most people change both of these consumables at the same, but in reality you should change two tips to one electrode since the tip takes the brunt of the amperage and arc flowing through the torch.

How do I clean the inside of a Plasma cutter?

With the Spectrum 875, 375 X-TREME and 625 X-TREME, there is a Miller exclusive called "Wind Tunnel Technology". Wind Tunnel Technology prevents abrasive dust particles from damaging internal components. There is an actual tunnel through the machine in which the parts of the machine that get hot are placed. All of the electrical components and boards are protected from the dirty air that is drawn into the machine thus extending the life of the plasma cutter. To clean the inside of the machine just take off the louvers on the front and back and use an air hose to blow out the wind tunnel.

Another Miller exclusive is called "Fan on Demand". The fan will only come on when the unit has heated to a certain temperature. This reduces the amount of airborne dust/dirt pulled through the unit, cuts down on the power bill, and reduces noise in your shop.

Miller also offers a custom cover for the 875. They are high quality covers that fit over the machine to protect your investment from water, mildew and abrasions. Available for the 375 X-TREME and 625 X-TREME is the X-CASE™, A durable, impact resistant hard case with additional storage space for Multi-Voltage Plugs, consumables, gloves, eye protection and more.

How big of a Plasma cutter do I need to buy?

Start by determining the type and thickness of metal you’ll be cutting and the desired cutting speed. Miller uses three standards: rated, quality and sever cuts. A rated cut is the thickness of mild metal that an operator can manually cut at a rate of 10 inches per minute (IPM). A quality cut is rated at a slower speed but on thicker metal. A sever cut is the maximum thickness a plasma cutter can handle. The travel speed is slower and the cut may require clean up.

What kind of input power will I need?

Miller Spectrum plasma cutters have a range of power options.

The Spectrum 375 X-TREME can operate off 115V or 230V. The Spectrum 375 X-TREME can easily switch between the two, since the operator only has to choose the correct Multi-Voltage Plug for the receptacle.

Others can automatically adapt to a wide range of voltages, single or three-phase and compensate for power fluctuations in the supply. The Miller Spectrum 625 X-TREME and 875/875 Auto-Line are 208 or 230V machines with 40 amps of output. They have Line Voltage Compensation (LVC), which will give you a range from 176 to 264V. The machines will automatically handle any line fluctuations between those voltages.

These machines use Miller’s Auto-Line™ technology. Auto-Line allows direct connection to ANY primary power level: 50 or 60 Hz, single or three phase, 208 through 575 VAC. Simply connect the power cord to the correct plug or junction box and start cutting. Auto-Line lets you plasma cut at any location, on any job site and in any country without worrying about opening and manually linking the machine or damaging the machine from incorrect hookup.

This means you can plug this plasma cutter in anywhere in the world. Even with brownouts or other power fluctuations, as long as the voltage stays anywhere in that range, the cutting quality is unaffected.

These types of units are especially suited for working in the field, using an engine drive’s auxiliary power. In the field, units without this type of technology are prone to erratic cutting arcs, frequent breaker trips and blown circuit boards because they can place a load on the line such that voltage levels drop below the plasma cutter’s operating range.

Can I plug a plasma cutter into a 110V outlet?

Yes, but only a limited amount of machines. The simple theory of what you put into the machine is what you can get out is true for any mechanical device that requires electricity to operate. The only plasma cutting machines that will run off of 110V will have up to a 27 amp output.

They will have a rated cut of 1/8" to 1/2". Miller offers the Spectrum 375 X-TREME, which will operate off of 110 or 220V and have a 1/2" rated cut with 27amps of output.

The Spectrum 375X-TREME is able to switch quickly between the two voltages. It uses Miller’s Multi-Voltage Plugs (MVP), which can be switched in a matter of moments, depending on the type of receptacle.

What about the higher voltages?

The Miller Spectrum 625 X-TREME, 875 and 875 Auto-Line is a 208 or 230V machine with 40 amps of output. It has Line Voltage Compensation (LVC), which will give you a range from 176 to 264V. The machine will automatically handle any line fluctuations between those voltages.

These machines use Miller’s Auto-Line™ technology. Auto-Line allows direct connection to ANY primary power level: 50 or 60 Hz, single or three phase, 208 through 575 VAC. Simply connect the power cord to the correct plug or junction box and start cutting. Auto-Line lets you plasma cut at any location, on any job site and in any country without worrying about opening and manually linking the machine or damaging the machine from incorrect hookup.

Can I run a plasma cutter off of a generator?

Miller plasma cutters are designed to operate off of generator power. Not all plasma cutters can do this because of the "Dirty Power" produced by generators. Dirty power means that the voltage being produced will fluctuate enough to cause a machine to shut down or even break because of the fluctuation. Miller Plasma machines have LVC or Line Voltage Compensation, which handles fluctuations of plus or minus 15% to perform very well off of engine, driven power.

What about portability?

In addition to the ability to work with available power supplies, consider the plasma cutter's weight and size. All of Miller’s plasma cutters weigh less than 100 lbs.

For the ultimate in portability, the Spectrum 375 X-TREME weighs only 18 lbs. and comes with its own shoulder strap to allow the operator to easily carry it.

What safety procedures do I need to follow?

Proper welding clothing should be worn, as well as a number 5 or 6 shade full-face shield. Good ventilation is a must just as when you are welding. Be aware of potential hazards involved with the process including, high voltages, noise, temperatures, flammable materials, fumes, ultraviolet radiation and molten metal.

What advantage does Plasma have over Oxyfuel?

Plasma cutting provides numerous advantages over Oxyfuel. It cuts faster; does not require a pre-heat cycle; produces a small and more precise kerf width (the width of the cut); and has a smaller heat-affected zone, which prevents the surrounding area from warping or damaging the paint.

The Plasma process also cuts any type of electrically conductive metal (the Oxyfuel process cannot cut stainless steel or aluminum). Plasma cutting is a cleaner, less expensive and more convenient method of metal cutting because clean, dry air is used for most plasma cutting applications.

What are the basic costs involved in Plasma vs Oxyfuel?

To get started in Oxyfuel you will need the complete torch set-up costing around $250. You will need an oxygen and acetylene bottle costing around $250 to own. The tips that have to be replaced over time will go for about $5. As you gas bottles are emptied they can be refilled for about $30 each. After all is said and done you still can only cut steel.

Plasma will require an initial cost $1100 to $2000 depending on what size machine you require. After purchasing the machine your air compressor will provide free air so the only additional cost will be tips and electrodes for about $11 for the pair.

Oxyfuel is going to be less expensive at the start, but as time goes on the purchase of gas, and the limitations will make it more expensive in the long run. Plasma has the initial cost of the machine but after that it is mostly tips and electrodes. So in the long run Plasma is going to be cheaper and more practical for cutting any metal that is electrically conductive.

Financing

What types of equipment and accessories can I finance through PowerLINE?

With the exception of <a href="/equipment/automation-systems">Miller Welding Automation Products</a>, all Miller branded equipment and accessories are eligible for the Miller PowerLINE 0% financing. Miller Welding Automation products, however, are eligible for the “Wells Fargo standard interest rate.*" See Wells Fargo for details or contact your Miller Representative.

*All financing is subject to credit approval and acceptance by Wells Fargo.

What are the rates/terms on the PowerLINE Financing?

0% financing for 12 months with 12 equal payments. 24 - 60 month payment terms are also available at specified interest rates. To quickly estimate your monthly payments use the <a href="/support/financing/calculator">payment calculator</a>. Customer's rate is locked for 90 days after credit approval. This rate is far superior to credit cards and extremely competitive with commercial lenders.

How difficult is it to gain financing through Wells Fargo vs. through my local bank?

Because Miller Electric Mfg Co. has already prearranged the financing with Wells Fargo, we know funds are available for lending. Because each customer's credit position is different, it is impossible for us to comment on the ease or difficulty of gaining financing from your local lending institutions. However, businesses are telling us that lenders remain conservative and credit is slow and hard to come by for equipment purchases. Bottom line, the program provides another very competitive, accessible and fast option for you.

Advantages of the program?

- Easy application process—you get an answer in days vs. weeks or months
- The program offered through Miller Electric Mfg Co. — the same reliable company you count on for equipment
- Minimum amount is only $10,000—much lower than similar programs offered elsewhere

Who owns the equipment?

You own the equipment after you make the last monthly payment — no balloon payments at the end.

Who do I make payments to?

Payments are made directly to Wells Fargo.

Who completes the application to Wells Fargo — me or my distributor?

You must get the form from your distributor along with an equipment quote and the distributor will send the completed application to WFFCF.

Why not make the financing form available online?

We are encouraging you to make personal contact with your distributor to make sure you have the best equipment for your applications and accurate estimates for your financing. In addition, your distributor will be available to support your equipment after the sale.

Does 100% of the equipment have to be Miller — or can I include other manufacturers’ welding equipment on my financing project?

The program can only be used for Miller branded welding/cutting equipment and accessories.

Does the 0% finance program allow me to buy Miller equipment directly from Miller Electric?

No. You must purchase the equipment through a Miller-authorized distributor.

What are the up-front costs associated with financing equipment?

After financing is approved, the contract along with the advance payment invoice will be included in the document package. A feature of financing is the low start up costs of only the advance payment. Note: The documentation fee of $100 will be billed on the first monthly invoice once lease has commenced.

Are the interest charges calculated simple interest?

Yes.

Can I finance tax, freight, and installation charges?

Yes.

Are there any fees associated with paying off a contract early?

If you wish to pay the contract off early with WFFCF, the payoff amount will be the outstanding balance plus any late charges and taxes due and you will be rebated any unearned interest.

If you decide to pay off the contract in less than half the original term, (for example, month 10 of a 36-month contract) you are quoted the principal amount that is due plus a $300 early close out fee. You are still rebated the unearned interest.

Are there any UCC1 and Security agreements filed against the equipment and are there charges for this?

Yes, we do file the UCC1 and Security Agreement. No, there are no charges to you for this service.

If my request for financing is declined, am I still responsible for the $100 documentation fee?

No.

Will I receive a payment book?

Monthly invoices will be sent.

When is my monthly payment due?

Monthly payments are due on the 1st of every month.

Can I get set up on an ACH (automated clearing house) program where my monthly payment is automatically extracted from my account?

Yes.

Can I pay down extra principal on the loan?

No, it is not possible to send in extra money and have it applied to the principal amount.

If I am considering a purchase, how long is the interest rate locked?

Your interest rate is locked for 90 days from the day you are credit approved. Once you sign the contract, the rate is locked for the entire term.

How are my monthly payments calculated?

Payments are calculated based on the term selected and the dollar amount of the equipment being financed. To quickly estimate your monthly payment, use the <a href="/support/financing/calculator">payment calculator</a>.

Can educational institutions take advantage of the PowerLINE 0% financing?

No, Educational Institutions are not eligible for the PowerLINE 0% financing, but ask about Miller’s educational discount! Miller offers a discount on equipment sold to chartered non-profit educational institutions. Contact your local <a href="/where-to-buy">Authorized Miller Distributor</a> to see if you can save.

Insight

How is welding information different than arc data monitoring?

Arc data is only that: data in the form of numbers. Insight Core and Insight Centerpoint systems translate arc data automatically in real time, delivering actionable information you can use to make effective business decisions.

I already collect weld data. Why do I need another data-collection solution?

If you're collecting weld data manually, you know the process is time-consuming. It can also be prone to errors. It is difficult to capture all the information you need to identify opportunities for improvements in weld quality or productivity, and it can't deliver information in real time. Manually collected welding data also needs to be compiled, interpreted and analyzed before decisions can be made. Insight Core™ and Insight Centerpoint™ can eliminate these pain points.

What's the difference between Insight Core and Insight Centerpoint?

Insight Core is focused on providing basic productivity and quality information about the welding process. Insight Centerpoint brings advanced process control information into the actual weld cell to help manage the welding and fabrication process. Some manufacturers benefit from a combination of both Insight Core and Insight Centerpoint.

Do I need to purchase machine?

Current Miller MIG 14-pin compliant power sources can be connected to Insight Core using field upgrade modules; new Axcess® machines can be ordered with Insight Core factory installed. Additionally, a module for Insight Centerpoint is available for Axcess machines as either a field upgrade or factory installed.

How complicated is it to install an Insight upgrade on my machines?

Installation doesn't have to be complicated. Insight systems can be easier to get up and running than other welding information management systems. Insight Core connects via either wired Ethernet or an integrated Wi-Fi feature. Insight Core also includes convenient USB support for device setup, data downloads, and firmware updates. Axcess E with Insight Centerpoint is Wi-Fi capable using an external wireless switch (not included).

Do I need to install special software to use an Insight system?

Insight Core requires no software: this system securely delivers information and reports to virtually any Internet-enabled device in the world, including tablet computers and smartphones. Insight Centerpoint has advanced welding and fabrication management processes that operate using dedicated PC software installed locally on the shop floor on a dedicated server.

Different ways?

Insight dashboards can provide an easy-to-understand snapshot of your welding operation's productivity, quality and progress toward goals. When more-detailed information is required, Insight can deliver it in easy-to-read reports, tailored to meet your specific needs.

What can I do with welding information?

Welding information provides valuable insight into your operation that can help make it more competitive and more profitable.

Insight Core systems:

    Deliver vital facts about weld arc details (arc-on time, deposition, quality, process parameters)
    Reveal information about adherence to established weld thresholds for amps, volts, wirefeed speed
    Show your operation's progress toward productivity goals
    Notify you of key events in real time
    Deliver reports comparing any combination of machines and weld cells

Insight Centerpoint systems:

    Have advanced monitoring and process control capabilities
    Guide operators through complex weld processes and monitor each step of the way
    Alert/notify operator of missed and out of sequence welds

With Insight systems, you'll get valuable information you can use to increase productivity, manage costs and improve weld quality.

Who can see my company's data?

Only persons to whom you give login credentials can see the data. Insight systems require input of a valid username/password combination before access to data is granted.

How secure is my data?

Insight Core data is held securely in a Microsoft data center. This data center has ISO 27001-2005 accreditation with backup power generation capability and co-location redundancy. Insight Centerpoint data is stored on customers' on-site computers.

Is there a subscription fee for Insight Core?

Insight Core doesn't require any subscription fees to access its cloud-based data storage, which maintains a rolling 90-day window of data.

Oxy-Fuel Torch Operation

When extinguishing the flame, do I have to turn off my oxygen first?

You can shut off either gas first, but turning off the oxygen first and the fuel gas are most commonly recommended.

Why does my torch and/or tip overheat?

The two most common causes of torch and tip overheating are:

- Incorrect flame adjustments

- Insufficient gas supply to the torch

An incorrectly adjusted flame is among the most common causes of overheating. If the torch and valves do not have enough gas flowing through them, the flame will lack the velocity necessary to push and burn away from the tip. As a result, the flame recedes and starves into the tip resulting in overheating. And because flames can reach up to 6,000 Fahrenheit, that heat is easily transferable from the tip to the torch.

Using the appropriate amount of oxygen can also help prevent overheating, as oxygen has a cooling effect on the tip as it passes through the torch and tips.

Tools such as flashback arrestors or check valves, while necessary for safety, can restrict the flow of gas and oxygen to the torch and cause overheating. Standard sized flashback arrestors will work well with tips up to a certain size, but a high-flow flashback arrestor should be used with larger tips. These high-flow models feature a larger diameter that created less gas flow resistance and therefore, less opportunity for overheating.

How do I properly adjust the flame on an acetylene cutting tip?

When using acetylene, the most common fuel gas, you must first purge the system by opening the fuel valve and allowing it to run for approximately 3 seconds for every 25 feet of hose length. Close the torch fuel valve and purge the oxygen hose by using the same process. Once you have purged the system, you are ready to light the torch.

When using a combination style torch with a cutting assembly, keep the torch handle oxygen valve fully open to prevent restricted flow during the cutting process. Next, open the fuel valve slightly and ignite the gas with a friction style lighter. Continue opening the fuel gas valve until there is sufficient gas flow to prevent the tip from starving. Open the fuel valve until the soot, which is discharged from the flame, disappears or until the preheat flames just begin separating from the tip. Next, open the oxygen valve until what are known as acetylene feathers (long white flames) are reduced in length to where they just disappear in the small bright luminous cones, that is a neutral flame.

What gas pressures should I use for my tip?

Unless you are using an extremely large cutting tip or a heating tip, you can typically set your fuel gas pressure at 10 pounds per square inch (psi) and your oxygen at the required pressure for the tip being used without any problem. With welding and brazing tips, both pressures are typically set the same. A common error is to set cutting oxygen pressures too high, which can lead to turbulence in the cut, increase the amount of slag produced and decrease economy.


The best precaution against pressure related problems is to refer to the manufacturer’s cutting guide for specific information on your gas and application, or seek advice from your local welding supply distributor.

What type of fuel gas should I use?

Choosing a gas depends on a number of variables, including: applications material thickness, material coatings, and the cost or availability of the fuel gas. The best way to determine the best fuel gas for you, in terms of both economics and performance, is to test each gas over a set period of time. Compare the results to see how much work you were able to complete, how much gas you used and the overall cost for the gas at that time before making your decision. 


If you use different gases for different applications, you can typically use the same torch for each. There are some torches on the market that may require a mixer change to correspond with different gases. Miller's torches require only a tip change when changing fuel gases.

Can I use (city) natural gas for my oxy-fuel application?

Yes, however, natural gas runs through utility pipes at an extremely low pressure and often will not provide the necessary pressure for cutting. When using a torch for heavy duty applications, you may need to run a separate fuel gas manifold line so that enough gas is forced by pressure to the tip to prevent the flame from starving. An injector style torch may also be used for low-pressure city gas.

Where is the best place to locate add on flashback arrestors in my system?

Because flashbacks often occur in the hose area right behind the torch, the best and safest place to locate an add-on flashback arrestor is on the torch handles. When using larger tips with flashback arrestors mounted on the torch, it may be necessary to increase the oxygen pressures 10 to 20 percent to ensure sufficient gas flow.

What is the difference between a check valve and a flashback arrestor? Do I need both?

Flashback arrestors are typically constructed with a sintered filter to absorb the flame in the event of a flashback and typically have a reverse flow check valve integrated into them. The check valve is designed to prevent gases from flowing in the wrong direction which could produce a flashback. In the event that a flashback still occurs, the sintered filter on the flashback arrestor is designed to pull the heat energy away from the flame and extinguish it.

What size fuel gas tank do I need to run my heating tip safely?

The type of fuel gas and the consumption requirements for your specific heating tip will determine the size of tank you need. The typical rule for acetylene is that the tip requirement is one-seventh of the cylinder’s capacity per hour. For example, if your tip requires 20 cu.ft. of acetylene gas per hour, then is requires a cylinder with a minimum capacity of 140 cu. Ft ( 20X 7=140). When using alternate fuel (LP) gases you will need to know how much gas a certain LP tank size can produce at a given temperature for the tip being used. Typically LP tanks can produce greater gas volumes and LP gases are not as unstable as acetylene. Temperature has a major effect on gas flow from LP tanks, including Propane and Propylene.

What is the difference between an "R" and a "T" grade hose?

“R” grade hoses may be used with acetylene gas and it is recommended that “T” grade hoses be used with LP gases such as Propane, Propylene and Natural gas.

ProHeat Rolling Inductor

How do I access the program setup screen for the Rolling Inductor?

To view the system setup screen for the Rolling Inductor, simultaneously press the Parameters and Program buttons. The following settings are available:

- Deg Units Displayed (°F or °C)

- Tolerance (±5 to 99)

- Travel Detect (On or Off)

- Control Mode (Manual, Temp, Time or Remote)

- Max Output (1 Kw to 35 Kw)

- System Lock (Yes or No)

(For more information on the setup screen, please consult the Rolling Inductor Owner’s Manual)

Can I get a full 35 kW of output power with the Rolling Inductor?

No, the Rolling Inductor is limited to 300 amps which results in about 20 kW of output power. If 35 kW at 100% duty cycle is desired, a two rolling inductor arrangement is required. The external cooler heat exchanger (300993) is recommended for two Rolling Inductor arrangements. (See owner’s manual for additional information on this topic)

If I already own a ProHeat 35, will the Rolling Inductor work with my system?

Yes, all ProHeat 35 systems are capable of running the Rolling Inductor, but if the system was purchased before August 2014 (serial number prior to ME320092G) a software update is required to run the Rolling Inductor and a hardware update is required to run the Travel Detect System (301183). If an update is needed, call Miller’s service department at 920-735-4001 for more information on how to update your systems software.

Will the Rolling Inductor work with the Intellifire 250 or other induction power sources?

No. The ProHeat 35 is the only power source that works with the Rolling Inductor.

Can I use the recorder to document heating with the Rolling Inductor?

Yes. If the Rolling Inductor is used with compatible temperature measurement devices (customer supplied) you can record heating temperatures. Measurements should be taken within two inches of the Rolling Inductor.

What happens if I run the Rolling Inductor without rolling the pipe or moving the induction head?

Depending on output, material type and material thickness, if the Rolling Inductor remains stationary for too long it can overheat the work piece and cause irreversible damage to the work piece and Rolling Inductor. For this reason it is extremely important to ensure that either the work piece or Rolling Inductor is moving at all times. Using the Travel Detect System (301183) helps minimize the chance of overheating a stationary, object by constantly sending feedback to the power source and limiting output if limited or no motion is detected.

What's the difference between the mounting arm and mounting stand that Miller offers?

The mounting arm (301119) allows heating from the top side of the pipe and will provide the most amount of flexibility and configurability. The mounting stand (301258) is ideal for heating from the bottom of the pipe.

How fast can I expect my part to reach its target temperature?

There are many variables that affect the time to temperature of the part being heated; the thickness of the part, amount of surface area, travel speed and type of material being heated.

Example: A carbon steel pipe with a diameter of 12” and a wall thickness of ¾”, traveling at 34 ipm, took under 4 minutes in our lab testing to reach 400°F on the entire interior of the pipe.

How do I determine a travel speed for optimal heating?

A larger diameter part should be rolled faster because it will dissipate heat quickly between passes of the induction head. A smaller part can be rolled slower because it will dissipate less heat between passes of the induction head. Speeds below 15 ipm will take longer to heat because the power ramp rate is limited. Below 30 ipm maximum output is limited to about 1 kW per ipm of travel speed.

Do all four Rolling Inductor wheels need to be in contact with the work piece at all times?

Power coupling to the part decreases as the distance to the part increases. Maintaining constant distance between the rolling inductor and the work piece will ensure consistent heating, using the wheels is the best way to maintain a constant distance. The wheels should be the only part to contact the work piece, if any other part of the rolling inductor stays in contact with the work piece damage can occur.

Does it matter which way I roll the pipe/work piece when using the Rolling Inductor?

When using the Rolling Inductor always roll away from the power cable. (Clockwise when the cable is exiting left and counterclockwise when the cable is exiting right)

What applications are best suited for the Rolling Inductor?

While there is no set configuration for the Rolling Inductor, primary applications include preheating fabricated pipe sections, preheating tower bases and preheating longitudinal submerged arc welding passes.

Who can I contact for additional support or information about the Rolling Inductor?

For more information regarding setup, troubleshooting, or operation of the Rolling Inductor contact Miller’s service department at 920-735-4001

Tier 4

What is Tier 4 Final (T4F)?

T4F is a significant reduction in the EPA's allowable levels of exhaust emissions from diesel (not gasoline) engines. To meet T4F regulations, new diesel engines require significant modifications, including the installation of exhaust after-treatment devices. The result is fewer pollutants emitted by those engines and a cleaner environment.

Which Miller® diesel engine-driven welder/generators are affected by T4F?

Miller diesel engine-driven welder/generators affected by T4F include the Big Blue® 400, Big Blue® 400 Eco Pro, Big Blue® 500, Big Blue® 700 Duo Pro, Big Blue® Turbo and Big Blue® AirPak. Our new T4F products include the Big Blue® 800 Duo AirPak, Big Blue® 800 Duo Pro, and Big Blue® 500 Pro.

Are other countries adopting T4F standards?

Each country has its own emissions rules, but only the U.S. is adopting T4F standards at this time. Canada has deferred implementation until January 1, 2019.

How long has Miller known about these EPA regulations, and what has Miller done to prepare for them?

The EPA's first set of emissions regulations affecting diesel engines in the horsepower ranges used by Miller had an effective date of January 1, 1998. Since then, increasingly stringent emissions regulations have been implemented. T2 became effective in 2004 and was followed by T3/T4i in 2008. In each case, both Miller and the engine manufacturers made the modifications necessary to ensure full compliance.

Miller has prepared for the T4F changes not only by ensuring full compliance of affected diesel engine-driven welder/generators, but also by increasing the output capabilities of welder/generators with diesel engines rated under 25 horsepower, which meet a different level of Tier 4 EPA regulations. In improving the full line of Miller® diesel-powered welder/generators, we hope to make more options available to our customers and minimize the impact that the T4F regulations may have on them.