Ajax TOCCO Toccotron AC Owner'S Manual Download

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Toccotron AC

Processes

Description

Induction Heating Power Source

Induction Heating

OM-229 158L

2011

−

File: Induction Heating

Visit our website at

www.AjaxTocco.com

Summary of Contents for Toccotron AC

Page 1: ...Toccotron AC Processes Description Induction Heating Power Source Induction Heating OM 229 158L 2011 11 File Induction Heating Visit our website at www AjaxTocco com...

Page 2: ......

Page 3: ...2 Specifications 11 4 3 Selecting A Location 11 4 4 Tipping 12 4 5 Electrical Service Guide 12 4 6 Connecting 3 Phase Input Power For 460 575 Volt Models 13 4 7 Connecting 3 Phase Input Power For 400...

Page 4: ...8 4 EMF Information 29 SECTION 9 DIAGNOSTICS TROUBLESHOOTING 30 9 1 Operator Interface Indicators 30 9 2 Limit Conditions 30 9 3 Limit Condition Codes 31 9 4 Fault Conditions 31 9 5 Fault Condition Co...

Page 5: ...OSHA 29 CFR 1910 147 see Safety Standards Use only nonconductive coolant hoses with a minimum length of 18 inches 457 mm to provide isolation Properly install and ground this equipment according to it...

Page 6: ...arts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary...

Page 7: ...ite www nfpa org and www sparky org CanadianElectrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS...

Page 8: ...les que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions...

Page 9: ...n m tal loign s de la t te de l enroulement pendant le fonctionnement Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter...

Page 10: ...des malformations cong nitalesou autres probl mes de procr ation Se laver les mains apr s toute manipulation Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiq...

Page 11: ...bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas co...

Page 12: ...sives 3 1 Keep flammables away from heating operation Do not heat near flammables 3 2 Heating sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 4 Breathing...

Page 13: ...d the instructions before working on the machine 6 Connect green or green yellow grounding conductor to ground terminal 7 Connect input conductors L1 L2 And L3 to line terminals 194 466 1 2 4 5 3 6 7...

Page 14: ...Hz Hertz Circuit Protector Output Increase Line Connection I1 Primary Current I2 Rated Current U1 Primary Voltage U2 Load Voltage Read Instructions Three Phase Static Frequency Con verter Transform er...

Page 15: ...60 V 575 V kVA kW 5 To 30 kHz 35 kW At 100 Duty Cycle 350 A RMS 700 V RMS 35 kW At 100 Duty Cycle 700 A RMS 700 V RMS 2 5 To 50 h 60 A 50 A 40 A 39 37 Length 36 3 4 in 993 mm Width 21 1 2 in 546 mm He...

Page 16: ...uit Breaker Rating In Amperes 1 Circuit Breaker 1 Time Delay Fuses 2 70 61 45 Normal Operating Fuses 3 80 70 60 Min Input Conductor Size In AWG 4 6 8 8 Max Recommended Input Conductor Length In Feet M...

Page 17: ...ity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yel...

Page 18: ...Welding Power Source Input Power Con nections 2 Strain Relief Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor C...

Page 19: ...229 158 Page 15 804 597 A 4 8 Power Source Output Connections 1 1 Output Bus Bars Use supplied 1 4 20 nuts to make electrical connections to the output bus bars as required by the specific applicatio...

Page 20: ...tact closure to A completes 24 volts DC contactor control circuit C D E G Remote Output Control Command reference 10 volts DC Control circuit common Input command signal potentiometer wiper or 0 to 10...

Page 21: ...on 1 Incycle Common 2 Incycle Normally Closed 3 Incycle Normally Open 4 Auxiliary Common 5 Auxiliary Normally Closed 6 Auxiliary Normally Open 7 Limit Common 8 Limit Normally Closed 9 Limit Normally O...

Page 22: ...ource e g insulation has broken down on a heating coil causing the conductor to come into contact with the workpiece or a heating coil touches the workpiece causing a short in the output circuit This...

Page 23: ...otector 1 115 VAC 2 5 A Single Phase AC Receptacle RC1 2 Supplementary Protector CB1 2 5 A The receptacle supplies nominal 115 volts AC auxiliary power Maximum output from receptacle is 2 5 am peres C...

Page 24: ...em fault condi tion 9 Limit LED LED lights to indicate a system limit condi tion 10 Heat On LED LED lights to indicate the power source out put is energized 11 Run Button Use button to run a heating p...

Page 25: ...stem Setup screen simultaneously press the Parameters Hz V A kW and Program buttons and the following screen appears on the display Time Resolution Seconds SETUP1 KW Second Alarm No Min 0 Max 9999 KW...

Page 26: ...is Yes Remote Enable press the Increase or Decrease button to select a remote command source The factory default is No System Lock press the Increase or Decrease button to lock or unlock the operator...

Page 27: ...ble are Timed Remote or Manual 6 4 1 Time Based Control Time basedcontrol operates the system and controls the heating process based on programmed time and power voltage current or energy values An au...

Page 28: ...ower selected in the set up screen for a period of up to 99 hours 59 minutes 59 seconds or infinity 6 4 4 Auxiliary Relay The Auxiliary Relay is fully programmable for use in controlling auxiliary equ...

Page 29: ...5 3 Manual Control Mode Manual Power 0 0 KW CycleTime 00 00 00 Status Stopped During active operation Power shows the actual power delivered from the power source Cycle Time shows the elapsed time in...

Page 30: ...utton indicator LED illuminates to indicate no heating cycle is in process The display defaults to the Run Status screen from the last program used and the Run Status button indicator LED illuminates...

Page 31: ...Routine Maintenance Disconnect power before maintaining Maintain more often during severe conditions Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 3 Months...

Page 32: ...Disconnect input power conductors from deenergized supply line BEFORE moving an induction heating power source SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER removal of input power Turn...

Page 33: ...he State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compou...

Page 34: ...system is outside the range of its optimum operating conditions or parameters Should a limit condition occur during operation the yellow Limit LED will flash to indicate a problem If the active scree...

Page 35: ...rten extension cable Increase insulation width L09 Output Current Limit Tighten blanket against pipe surface L10 Output Current Limit Increase number of turns Decrease coil space Tighten cable on insu...

Page 36: ...rvice required F77 Power Source Internal Comm Fault Service required F78 Output Current Sense Fault Check for loose open output connection 9 6 System Diagnostic Screens Additionalsystem diagnostics ar...

Page 37: ...Therm5 Open not used ExtInt This is the status of the relay contacts for a remote protection device OFF ON The third diagnostic screen is available by again pressing and holding the Run Status button...

Page 38: ...ct fan motor FM3 1 Current Source Interconnect Board PC4 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC4 as shown until voltage drops to near 0 zero volts If the cap...

Page 39: ...ng Out Inside Of Unit Turn Off welding power source and disconnect input power Remove wrapper and be sure input capacitors are discharged Blow out inside of unit Blow out fan motors in right side pane...

Page 40: ...OM 229 158 Page 36 SECTION 10 ELECTRICAL DIAGRAM Figure 10 1 Circuit Diagram...

Page 41: ...OM 229 158 Page 37 219 029 B...

Page 42: ...468 DOOR primary board 1 7 189 491 SPACER hinge 1 8 168 343 HINGE cont polyolefin copolymer 1 9 222 106 BRACKET mtg fan 1 10 FM3 236 263 FAN muffin 24VDC 3000 RPM 130 CFM 1 11 206 270 INSULATOR side...

Page 43: ...face 1 7 S1 244 920 SWITCH tgl 3pst 40A 600VAC SCR Term Wide TGL 1 8 252 731 LABEL warning read labels on off storage temp 1 9 115 440 STANDOFF no 6 32 14 10 224 143 GASKET meter lens 1 11 228 168 PLA...

Page 44: ...put block 2 10 228 169 PANEL rear output 1 11 186 523 STRIP mtg output assy 2 12 218 693 ASSY output plate 2 13 229 153 INSULATOR output TOCCOTRON AC 1 14 196 245 ENCLOSURE output 1 15 196 246 ENDPLAT...

Page 45: ...ANSFORMER hf 1 7 T1 227 065 TRANSFORMER hf 400V model 1 8 216 629 BRACKET fan 1 9 FM1 FM2 222 728 FAN nuffin 48 V 2 10 RC4 115 090 HOUSING PLUG PINS service kit 1 11 217 992 BAFFLE air bottom 1 12 224...

Page 46: ...p 1 8 PC5 239 257 KIT circuit card assy intrcnct bridge 1 9 208 591 SCREW M 5 8X 12 soc hd torx stl pld sems 12 10 212 038 SCREW M4 7 x 8 5 pan hd phl stl pld 8 11 F1 225 514 FUSE crtg 2 amp 600 V tim...

Page 47: ...tg hole 1 5 223 120 BLOCK term 115 amp 3 pole screw term 1 6 148 743 LUG univ w scr 600V 2 14 wire 250 stud 1 7 RT1 222 326 THERMISTOR ntc 30 k ohm at 25 deg C 34 in lead 1 8 083 147 GROMMET scr no 8...

Page 48: ...411 115 093 HOUSING PLUG SKTS SERVICE KIT 3 PLG47 115 091 HOUSING PLUG SKTS SERVICE KIT 1 PLG45 61 131 204 HOUSING PLUG SKTS SERVICE KIT 2 PLG111 112 121 132 141 142 131 054 HOUSING RCPT SKTS SERVICE...

Page 49: ...no 6 32 x 750 lg 250 hex 7 6 083 147 GROMMET scr no 8 10 panel hole 312 sq 500 high 2 7 RT3 222 327 THERMISTOR ntc 30 k ohm at 25 deg C 24 in lead 1 8 030 170 BUSHING snap in nyl 750 ID x 1 000 mtg ho...

Page 50: ...G77 119 115 092 HOUSING PLUG SKTS SERVICE KIT 2 PLG17 115 091 HOUSING PLUG SKTS SERVICE KIT 1 PLG18 116 131 056 HOUSING RCPT SKTS SERVICE KIT 2 PLG13 113 162 382 HOUSING PLUG SKTS SERVICE KIT 2 PLG14...

Page 51: ...RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work stat...

Page 52: ...Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circu...

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