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OPERATION AND

MAINTENANCE INSTRUCTIONS

4.2kW – 10kW Induction Heating Systems

LI Models 3542, 4048, 5060, 7590, 8310

PRECISION

INDUCTION HEATING EQUIPMENT

File Name

801-9526-00.doc

Part Number

801-9526

Revision P
ECN# 1501-33
By S.

Nelson

Approved

Date 01/19/2015

Содержание 3542

Страница 1: ...STRUCTIONS 4 2kW 10kW Induction Heating Systems LI Models 3542 4048 5060 7590 8310 PRECISION INDUCTION HEATING EQUIPMENT File Name 801 9526 00 doc Part Number 801 9526 Revision P ECN 1501 33 By S Nels...

Страница 2: ...nt Added Regulation Efficiency and Power Measurement content Rev N Added WEEE disclaimer content Rev P Added electrical warning to p68 Corrected contact information Ambrell Companies Ambrell www ambre...

Страница 3: ...HEAT 39 3 1 Rear Panel Connections 39 3 2 Serial Port RJ45 modular 45 3 3 Optional Equipment 53 3 4 eVIEW Induction Heating Software 55 3 5 Tap Adjustment 57 3 6 Re selecting Mains Voltage Range 59 4...

Страница 4: ...symbols indicate a step in a procedure manual sections lighted indicators on the equipment A notice that requires your special attention may pertain to safe operation of the equipment A notice that r...

Страница 5: ...results with Touch pad interface for control and programming Backlit LCD simultaneous display of up to four data fields Analog output user programmable to represent Coil current RF power or operating...

Страница 6: ...e safety codes The equipment requires a connection to earth ground and does not make use of neutral Failure to connect earth safety ground will result in a potentially hazardous condition Do not omit...

Страница 7: ...tate Your E stop switch must be isolated dry contact capable of switching 0 1A 24Vdc The power supply is fitted with an external rear panel jumper which must be removed to insert any safety switches r...

Страница 8: ...rface is conducted here Status LEDs indicate what your EASYHEAT is doing AC indicator is lighted when unit is turned on LCD display provides operating information navigation programming prompts START...

Страница 9: ...the internal temperature rises too high Cooling water is directed to and from the work head through the chassis and monitored by the power supply Circuit breaker This gang switch controls the mains c...

Страница 10: ...l shown and required wiring See 3 for instructions to change your transformer tap settings Water is directed through the work head to draw out excess heat developed naturally in the internal component...

Страница 11: ...lace RF cover to remove tubing push in on retaining rings pull out tubes Work head mounting base options Your work head has been fitted with a two part mounting insert which elevates and insulates the...

Страница 12: ...ounting plate re use or use new O rings PN 117 0021 insert in recessed face of work head secure coil with 4 screws provided tighten Rack panel Mounting Your EASYHEAT is mountable in your panel or 19 r...

Страница 13: ...ents these agents reduce efficiency of cooling If cooler is not supplied by us Install a pressure regulator and a particulate matter filter both non ferrous in the supply of your cooling water Do not...

Страница 14: ...the instructions in 3 6 We recommend that you install a fused disconnect switch not supplied by Ambrell in the branch circuit supplying the equipment Base your selection of fuses on the equipment name...

Страница 15: ...anguage suite EN ES FR DE IT this capability is reflected in this screen Firmware versions There may be instances where we need this information from you n nn represents the version numbers of the Dis...

Страница 16: ......

Страница 17: ...r EASYHEAT operates in this zone when you first apply power The factory settings enable you to get right to work heating parts by operating the front panel From the Home zone you can adjust output lev...

Страница 18: ...Untimed 0 0A 0kHz 100 1A Untimed 0 0A 0kHz 100 1A Untimed 100 1A 100kHz 1 3 Ready HeatOn Fault Ready HeatOn Fault 2 Ready HeatOn Fault 2 Timer cycle or continuous Setpoint required output level Output...

Страница 19: ...ton to scroll quickly to a new value press adjust until 10 00s secure unheated part in coil part not contacting coil do not hold press START HeatOn Ready Ready only when timer expires HeatOff remove h...

Страница 20: ...put power is turned on this displays the output in terms of RF coil power or current The output level can be shown in RF Amps or RF Watts press to toggle At the bottom right corner of the screen the f...

Страница 21: ...than 2 for suggested corrective step s W overscored displayed output power is outside a preferred tolerance band Increase tap for possible improvements Cap display you are attempting to adjust Setpoi...

Страница 22: ...the Home zone these are used to adjust Setpoint and Timer indicated with the display pointer Within the Control zone below use the up button to replay the start up screens to review firmware version...

Страница 23: ...notices construct and enact heating Profiles adjust for RF output stage configuration tap settings tank capacitor Each touch pad button is represented in the map showing the effect touching each one h...

Страница 24: ...nt panel Rear you attach your remote signaling source PLC relays etc to CTB1 at the rear and START with those signals RS485 4 Wire if Communication RS485 4 Wire below select this to start heating with...

Страница 25: ...only protocols supported at this time Use to select then to enable See 3 Serial Communications Contrast Adjust To change the contrast of the displayed characters lower number lighter characters Use to...

Страница 26: ...HeatOn ceases when STOP is pressed or when timer expires 1button HeatOn only while button is pressed or CTB1 signal closed ceases when button is released or CTB1 signal opens Control From Front Panel...

Страница 27: ...any previous Fault notices previous from last heat cycle use to change between F and C Once this screen is displayed press use to select operating features Adjust Profiles This lets you build up to fo...

Страница 28: ...ap changing instructions select the correct work head model 1600SP Series 800S Series 800P Series 400 Series 300S Series 300P Series 150 Series Custom This information provided by us to select capacit...

Страница 29: ...prove operation refer to 3 for further adjusting instructions HeatOn Limit Unit heating not meeting setpoint display output differs from setpoint by more than 2 for suggested corrective step s W overs...

Страница 30: ...ystem cannot meet your Setpoint It lets you know that output is being restricted due to the condition mentioned in the notice Cutback Mode may be displayed Cap Over Voltage Cap Over Current capacitor...

Страница 31: ...et A1 step Time ex sets A1 Time 10s press Note A1 data points are displayed use select A2 set A2 Start 100A set A2 End 200A set A2 Time 20s use select A3 set A3 Data points as shown Clears all data fo...

Страница 32: ...oftware controlled compensation may not have enough time to respond Longer heat cycles may also be effected for severely undertapped conditions To disable frequency compensation Enter the Control Zone...

Страница 33: ...ent safety is compromised Call your Ambrell office 6 months coolant level top off if required appearance flush replace if dark or cloudy system for signs of leaks repair 12 months coolant dump flush r...

Страница 34: ...tions are secure ensure tap wiring and internal settings agree if Ready turns off while heating see 3 5 remove all power and water from your system wait 5 minutes use Philips screwdriver to remove cov...

Страница 35: ...move cover from your workhead examine all connections in both sides of boxed areas ensure secure connections examine your coil mounting connections ensure secure connections Tighten all cap buss conne...

Страница 36: ...laboratory rather than real world conditions The EASYHEAT systems make use of Smartburst technology which allows users to approach these higher current limits in actual use under many real world cond...

Страница 37: ...How Your EASYHEAT Works 37 AMBRELL 801 9526 00 doc Precision Induction Heating...

Страница 38: ......

Страница 39: ...ur EASYHEAT requires electrical connections at TB1 and in some cases unit configuration from the touch pad This terminal block is where you make all hardware control and monitoring connections to your...

Страница 40: ...scroll to Auxiliary Out press to scroll through output modes and their respective scaled ranges Choices Power 0 20mA Power 4 20mA Amps 0 20mA Amps 4 20mA Frequency 0 20mA Frequency 4 20mA Disabled Sel...

Страница 41: ...ge supply to this terminal Electrical Touch pad Connect to internal solid state contacts to complete your indicator signaling shown READY pair closure Ready HeatOn pair closure HeatOn Fault pair closu...

Страница 42: ...restricted water path we may recommend the use of a bypass block with your work head Ask your sales representative In this case you may be required to complete wiring for an external flow switch sold...

Страница 43: ...sure initiates heating opening STOP signal halts heating Heating cannot commence whenever normally closed STOP signal is opened Case You use one external signal switch or isolated contact to control R...

Страница 44: ...ouch pad Using 0 10Vdc source left upper terminal negative lower terminal positive set jumper left illustration Using 4 20mA source right upper terminal negative lower terminal positive across both 25...

Страница 45: ...mmunity its performance with long data lines and its ability to address multiple units connected in parallel Converter Kit Purchased Separately The RS485 serial communication port is a standard featur...

Страница 46: ...tart From and Control From press until once this selection has been made press press to select Terminal Mode select for addressing default 1 press to modify 1 32 valid 0 used for broadcast cannot be s...

Страница 47: ...e such as EASYHEAT then select COM1 or appropriate for your device 38400 baud or appropriate for your device 8 data bits parity none stop bits 1 flow control NONE click OK Click Disconnect upper image...

Страница 48: ...ype 1 or your device address ENTER EASYHEAT replies If the EASYHEAT does not reply to this command select disconnect at HyperTerminal select Properties Connect To select another available COM port re...

Страница 49: ...looks like this 2 line display is arranged like this csv data arranged per this example the setting if required from the table below device address default 1 1 32 available 0 broadcast address all add...

Страница 50: ...ne Turns on the alarm function If after the programmed delay time as extinguished if the power falls outside of the minimum or maximum power levels the alarm symbol will be displayed ADDED V5 02 displ...

Страница 51: ...ts a profile to load and run Example select profile B Selectable profiles are A B C and D 1 ctl fileb ctl fpan none Selects control to be front panel 1 ctl fpan ctl rpan0 10 none Selects control to be...

Страница 52: ...ation to be RS485 1 start rs485 stat none Provides present system status messages 1 stat temp none Responds with heat sink and internal temperature of the power supply 1 temp temp c none Selects tempe...

Страница 53: ...l Touch panel STOP Gnd default jumper is removed from TB1 System Options Start From Rear Panel Control From Front Panel Start Type 2 button 2 light model Touch panel J8 set left illustration Remote In...

Страница 54: ...ing occurs only while you depress the switch in the second the footswitch starts a timed cycle Continuous Touch panel STOP Gnd Jumper retained START Gnd N O contact System Options Start From Rear Pane...

Страница 55: ...S So of ft tw wa ar re e eVIEW is a PC based application that interfaces with EASYHEAT and EKOHEAT power supplies eVIEW allows the operator to visualize analyze and store induction heating data while...

Страница 56: ...a csv file for easy exporting to spreadsheet applications Set alarms around all key heating parameters to identify deviations as they occur Capture external analog signals such as temperature eVIEW is...

Страница 57: ...J G H K J C A C B A C A C Tap 26 28 30 32 34 36 38 40 42 Wire X F F E Y C C J B D C C D D Cu G H K B A C A C B A B A H G A F J B E D C Tap adjustments are made with 3 wires X Y K and jumper s Cu which...

Страница 58: ...rmine present setting from previous table above example TAP 22 depending on the message select the TAP on the chart which is numerically higher or lower that the present setting use slotted screw driv...

Страница 59: ...voltage range for which your system has been configured If you have a need to move the system into a facility with a different mains voltage range follow these instructions 230V Models 440V Models 208...

Страница 60: ...hown to select lower mains range set J1 B J2 A to select higher mains range set J1 A J2 B replace unit cover and secure screws restore AC power Navigate to Menu Selection System Options select AC Volt...

Страница 61: ...ping with relevant regulations The end user must hand over the system to either a licensed private or public disposal company or must recycle the unit himself If the end user hands over the system to...

Страница 62: ...ions when lower percentage outputs are called for Pulse Width Modulation This technique is used on the EKOHEAT product line and is commonly used in the industry EASYHEAT products borrow from a techniq...

Страница 63: ...would be an open coil the run interval is kept very brief as this condition is seen as approaching a shorted coil While the generator may be able to maintain regulation at low levels and meet applica...

Страница 64: ...ated to mains input current and the circuit breaker limit without taking into account power module efficiency and power factor Both efficiency and power factor change with operating conditions While p...

Страница 65: ...d current probes and their errors It is recommended that load power measurements be performed instead of terminal power using calorimeter techniques These techniques will include the losses of coil co...

Страница 66: ...onstruction aluminum Finish front panel black painted Remote Heat Station Feature Value Units Dimensions1 130x286x146 5 1x11 3x5 7 WxDxH mm in Internal access philips head screws Mounting reference yo...

Страница 67: ...dels Model 3542 4048 5060 7590 8310 units AC Line Power 5 2 5 9 7 4 11 2 12 4 2 kVA AC Line Protection 25 30 30 35 35 A Frequency 50 60 Hz AC Line Voltage 1 187 230 or 230 264 Vac 3 1 Level determined...

Страница 68: ...mA Zin 250 see 3 Start closed provide isolated contact closure Stop open FLS closed opened contact Fault 19Vdc 0 1A E Stop open opened contact stop contacts rated for 24Vdc min required wetting curren...

Страница 69: ...Watts max rated Where Power in Watts Aux_out_mA max power in watts 20 mA output Watts 1 500 5 2 500 10 5 000 20 10 000 4 20mA Scale in Power mode Model 8310 Where Power in Watts Aux_out_mA 4 max powe...

Страница 70: ...example if Aux out is 3 59mA then 3 59 13 5 140 188 46 kHz mA output Frequency in kHz 0 140 3 180 5 12 302 20 410 4 20mA Scale in Frequency mode In 4 20mA scale Frequency_in_kHz Aux_Out_mA 4 16 875 1...

Страница 71: ...s flow system minimum 3 8 1 0 5 7 1 5 l m g m pressure2 2 8 5 5 40 80 bar lb in2 pH 7 pH conductivity resistivity 25 C less than 50000 greater than 2000 S cm solids less than 150 ppm 1 Water temperatu...

Страница 72: ...Fax 1 585 889 4030 United Kingdom Ambrell Ltd Phoenix Works Saxon Way Cheltenham Gloucestershire GL52 6RU salesuk ambrell com Tel 44 0 1242 514042 Fax 44 0 1242 312011 France Ambrell Sarl Tour S basto...

Страница 73: ...Technical Information 73 AMBRELL 801 9526 00 doc Precision Induction Heating...

Страница 74: ......

Страница 75: ...7 7 T Th he eo or ry y o of f C Co oi il l D De es si ig gn n remove this page and replace with 801 9038...

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