PPSTinc 12.5-135/400 User Manual Download Page 1

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Induction Power Supplies

12.5KW; 135 – 400 KHz

LCD Display

(Integral Heat Station)

User’s Guide

Model 12.5

-135/400

05/08

Rev D

Summary of Contents for 12.5-135/400

Page 1: ...Induction Power Supplies 12 5KW 135 400 KHz LCD Display Integral Heat Station User s Guide Model 12 5 135 400 05 08 Rev D ...

Page 2: ...d features 3 2 Getting started 6 3 Connections 8 4 Front panel description and operation 10 5 Programming and Status monitor 16 6 Load station tuning 22 7 APPENDIX A USER INTERFACE 25 8 Layout 27 9 Finding dew point 28 2 ...

Page 3: ... Allowed OFF Time 0 5s 1 2 Input AC line to line voltage 240V 10 3 50 to 60Hz AC line current 35A 240V AC power 14 5kVA 1 3 Physical Dimensions Depth Width Height 16in 41cm 20in 51cm 43 75in 111cm Weight 275lb 125kg approximately 1 Inverter output power i e includes power losses in heat station 2 Mainly limited by the rating of resonant capacitors Consult manufacturer for operating at output volta...

Page 4: ...tep for Programmed mode Elapsed time for heat period power meter 0 100 LCD Display Working mode and Messages for fault trip and limit Run time read outs for Power demand operating frequency capacitor voltage and inverter current Controls Switch and knob Push button switch for Heat ON OFF Single turn knob for power level Manual mode Pushbutton to reset trips Emergency stop button Program keys 21 ke...

Page 5: ...itch on inlet water Differential pressure switch between water inlet and outlet Safety Interlocks Emergency stop button or door switch opens the main circuit breaker 1 7 Load Quality factor of load Will operate with any load Q including resistive loads provided that the output frequency and voltage is within the specifications Connection Selectable between left and right Custom output connection p...

Page 6: ...y shut 1 Read this operation manual completely before using the power supply 2 Induction heating can be dangerous Obey all warnings on unit and in manual 3 Do not touch live electrical parts In operation this means the output connectors the work coil the work piece and any bus work or cabling connecting them WARNING These symbols placed at the outputs of the power supply warn of the electric shock...

Page 7: ...tion 0 3 Connect the heating coil and load to the output of the unit see section 4 4 Connect and test the cooling water supply as described in section 0 5 Read section 0to become familiar with the front panel controls 6 Do initial setups of the internal heat station as described in section 6 1 7 Do the tuning of the heat station as described in section 6 2 The power supply will not operate if the ...

Page 8: ...location 1 is on the left side of cabinet next to left blank cover The second location 2 is at right side rear Cut outs in cabinets will be available and cover plates will be removable to make it easy for drilling holes for power cables 1 3 A third cutout is provided for control wiring 2 3 2 Load The load can be connected to the left or right side of the power supply The unit is shipped with the o...

Page 9: ...de Keep the input towards the back of the unit and output towards the front of the unit location The unit will not operate if the water flow is reversed Turn on the cooling water flow and verify that it meets the minimum requirements as given in section 1 8 on page 5 Check for any water leaks on the inlet outlet and heating coil Tighten connections if necessary Also check for any water leaks insid...

Page 10: ...tifies and describes the various parts of the front panel 1 2 3 5 6 7 8 9 4 10 1 Fault Trip and Limit LEDs 2 Heat On Off LEDs 3 Program Indicator 4 Time Indicator 5 Power Indicator 6 LCD display 7 Reset button 8 Heat switch 9 Power Knob 10 Program Buttons Figure 3 Front panel layout 10 ...

Page 11: ... station components RES TRIP The circuit momentarily operated below the resonant frequency due to e g a short in the load or heat station component or poor tuning of the heat station components I C TRIP The inverter current momentarily exceeded the set maximum peak value due to e g a short in the load or heat station component of poor tuning of the heat station components Limit indicator This indi...

Page 12: ... LCD display MANUAL T 2 5S LOC POWER LIMIT P S 50 C V 500V I C 320A FRQ 370KHz Figure 4 LCD display layout 1st line Displays Control mode MANUAL CONT Indicates power supply working in manual continuous mode MANUAL T 0 0S Indicates power supply working in manual timed mode PROGRAMMED Indicates power supply working in programmed mode Selected job number display on Program status indicator LOC Indica...

Page 13: ...ot Identified by in Figure 3 The power pot sets the requested power level indicated as P S on LCD display The level of power output is indicated by the percentage on the POWER indicator LED This pot is disabled during PROGRAMMED mode operation 4 1 10 Program buttons Identified by in Figure 3 The program buttons are used to program and display jobs for the power supply to run automatically See sect...

Page 14: ... by pressing LEFT key for 1 sec or more to manual timed mode and the LCD T 0 0S will blink You can enter the time you want to change with numeric keys and then press ENT key to save 4 2 2 Programmed mode operation Select Programmed mode in the programming if current mode is manual see section 5 1 PROGRAMMED LOC POWER LIMIT P S 50 C V 500V I C 300A FRQ 370KHz Press START switch to start process the...

Page 15: ...PROGRAM menu Default password 0000 3 Use UP and DOWN key to move object item to program and select the item with ENT or SEL key to enter into the item 4 Press ESC key to exit program mode 5 1 2 Control mode 1 Select the item CONTROL MODE in PROGRAM menu 2 Use UP and DOWN key to move object item to program and select the item 3 Select each value with LEFT and RIGHT key and press SAVE key to save th...

Page 16: ...f TB1 on EXT TERM board 5V 100 EXT 4 20mA Output power controlled by current level of P DEMD terminal of TB1 on EXT TERM board 4mA 0 20mA 100 Terminated with 250 ohm internal When EXT 0 5V or EXT4 20mA selected SW2 must be set as same name on EXT TERM board FBK MODE Selecting source of object control power POWER CAP V INV C AUX 0 5V AUX 4 20mA When EXT 0 5V or EXT4 20mA selected SW3 must be set as...

Page 17: ...c or more STEP 1 29 Enter the values of power level time for each step POWER 0 100 The power level will ramp from the last power level to the power level requested TIME 0 1 6399sec Note Enter 0 for the values of power level time both at a step to stop the job process Other steps after this step shall be ignored even they contained any values 5 1 5 System parameters Setting system functions 1 Selec...

Page 18: ...Start frequency Setting start frequency 135 440 kHz 1 Select START FREQ in the PROGRAM menu 2 Enter frequency of start and press ENT key to save the start frequency and return to PROGRAM menu 3 Press ESC key to return to PROGRAM menu without setting change 5 1 7 Pass word Changing password 0000 9999 Default Password is 0000 1 Select PASSWORD in the PROGRAM menu 2 Enter 4 digit password and press E...

Page 19: ...ay history events of Power supply Stores and displays the numbers of failed events that occurred in the heating process TURN ON Stores time of power on of power supply hour minute HEATING Stores time of Heat on hour minute PRESS FAIL Stores failure of differential pressure of cooling water TEMP FAIL Stores if exceeding temperature of cooling water INV FAIL Not activated for this power supply SW TH...

Page 20: ...unit operating at full power 25kW at the desired frequency user specified between 135 kHz and 400 kHz without any indicators lit 1 Ensure that the heat switch on the front panel is OFF state that the program POWER CONT LOCAL and that the power level knob is turned completely counter clockwise Check that the cooling water is turned on The unit will not deliver power if the minimum differential wate...

Page 21: ...RQ LIMIT disappears on the LCD at full power Decrease the turns in quarter turn increments by using the sliding bars as described in section 6 4 5 If the inductance changes of the previous step causes the frequency to go out of the acceptable range adjust the capacitance and return to step 1 6 Increasing the series inductances until the current reading is at minimal at full power will optimize the...

Page 22: ...rt from the top or bottom as indicated in Figure 4 Insert and tighten the mounting screws four per capacitor It is recommended that the capacitors be mounted in the positions closest to the side used for the output and no less than 4 capacitors used Load capacitors close to each other in groups to maximize current sharing When using the series parallel capacitor rail configuration add and remove c...

Page 23: ...the turns bar and shorting bars for changing the turns in quarter turn steps Move left on the table to decrease the inductance and right to increase the inductance Always place both the shorting bars in the same position Example If the initial setup was for ten turns shorting bar not installed and the turns need to be decreased with a quarter turn install the shorting bar in the bottom B position ...

Page 24: ...fine tuning Inductance Decrease Increase Turns bar 6 6 6 6 7 7 7 7 8 8 8 8 9 9 9 Shorting bar T M B T M B T M B T M B 1 Turn selection bar 2 Twelve turns position 3 Shorting bar in the bottom B position 1 3 2 Figure 5 Adjusting the series inductor 24 ...

Page 25: ...e wiper and terminal GND ground to the bottom of the pot P DEMD The voltage level at this terminal controls the command reference 0 volts is minimum and 5 volts is maximum A PLC can be connected to this terminal with its reference to GND This terminal applies to the power control mode EXT 0 5V or EXT4 20mA and SW2 must be set as same mode GND Common terminal for input signals ground 7 1 2 Analog s...

Page 26: ...lock is enabled in the program RESET Connecting terminal RESET and terminal COM will issue a fault reset if the external reset is enabled in the program COM Common terminal for input contacts 7 2 2 Relay output contacts TB3 HEAT Closes while power supply is in heating cycle FAULT Closes when power supply is in a fault or tripped condition READY Closes while power supply is in stand by RELAY LAMP L...

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