Ambrell EasyHeat 0112, Technical Handbook

Page 1: ...Technical Handbook Induction Heating Systems for 1 2kW 2 4kW Models 0112 0224 File Name 801 9309 doc Part Number 801 9309 Revision Rev F ECN 1606 08 By Mike Bond Approved Dan King Date 06 28 2016...

Page 2: ...converter kit information Rev F ECN1606 08 was written to Correct the Electrical Equipment Input table Ambrell Corporation United States 1 585 889 9000 Ambrell Ltd United Kingdom 44 0 1242 514042 801...

Page 3: ...hnology 31 3 Customizing Your EASYHEAT 33 3 1 Rear Panel Connections 33 3 2 Optional Pendant 38 3 3 Serial Control optional Error Bookmark not defined 3 4 eVIEW Induction Heating Software 48 3 5 Tap A...

Page 4: ...t A notice that requires your special attention may pertain to safe operation of the equipment A notice that requires your special attention due to potential hazards to personnel or property EASYHEAT...

Page 5: ...red no DIP switches used Free Front configuration co locates all utilities at the rear The power from your supply can be controlled manually from the front panel remotely by your signals provided to t...

Page 6: ...of switching 3A 24Vdc The power supply is fitted with an external rear panel jumper CTB1 15 16 which must be removed to insert any safety switches required High Temperatures take steps to prevent per...

Page 7: ...pply RF energy to your part attaches here Compression fittings for tubing are provided A coil kit is supplied with some orders Touch pad Display Status LEDs indicate what your EASYHEAT is doing AC ind...

Page 8: ...input and output signals 3 Heat sink C A heat sink is used with your cooling water to extract heat from internal components Power switch circuit breaker D This rocker switch completes the line connect...

Page 9: ...emblies from heat station terminals retain for future use locate work coil apply nuts and ferrules insert coil at the heat station connections assure that coil is fully seated in the fittings assure t...

Page 10: ...ing the water to pick up the excess heat and transfer it either to drain or to cooling to be recycled back to the equipment Follow these important restrictions If used fill re circulating system with...

Page 11: ...let turn power switch ON Start up display Upon power up certain important information about your EASYHEAT is displayed Output power capability Depending on the unit you purchased 1kW RF Power or 2kW R...

Page 12: ...Introduction 12...

Page 13: ...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 levels set the timer and turn RF power on an...

Page 14: ...00 1A Untimed 0 0A 0kHz 100 1A Untimed 100 1A 100kHz 1 3 Ready HeatOn Fault Ready HeatOn Fault 2 Ready HeatOn Fault 2 Status LEDs indicate what your EASYHEAT is doing READY waiting to heat no faults d...

Page 15: ...adjust until 10 00s 10 00s 10 00s 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 heated part from coil...

Page 16: ...the actual RF output always 0 0 when the heat is turned off When the output 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...

Page 17: ...ion to improve 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...

Page 18: ...hese are used to adjust Setpoint and Timer indicated with the display pointer Within the Control zone below use either button to replay the start up screens to review firmware version to adjust the RF...

Page 19: ...ture Fault 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...

Page 20: ...ront 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 wi...

Page 21: ...anel To prevent changes to settings No Yes disables all buttons except START STOP select and follow instructions enter 39889 code To unlock press while heat is off re enter code Alarm Limits Alarm Lim...

Page 22: ...Control From Control From Control From Control From Front Panel during HeatOn RF output follows setpoint entered at front panel Rear Panel your analog signal controls output File A use one of four pro...

Page 23: ...t heat cycle use to change between F and C Once this screen is displayed press use to select operating features Adjust Profiles Adjust Profiles Adjust Profiles Adjust Profiles This lets you build up t...

Page 24: ...and capacitor changing instructions 4 select the correct heat station model 1000S 1000P 1000 800S 800P 400 300S 300P 150 Custom This information provided by us to select capacitance to adjust to sele...

Page 25: ...T command received outputting power per settings Since both are lit output is within acceptable margins It may be possible to achieve a more efficient configuration for possible suggestion to improve...

Page 26: ...How Your EASYHEAT Works 26 to Control zone Status then for fault notice AC Power indicates EASYHEAT is ON see the Status screen for notices...

Page 27: ...t is being restricted due to the condition mentioned in the notice Cutback Mode may be displayed Cap Over Voltage Cap Over Current capacitor exposed to too much voltage reduce Setpoint Contact Us Heat...

Page 28: ...press Note A1 data points are displayed use select A2 set A2 Start 50A set A2 End 200A set A2 Time 20s use select A3 set A3 Data points as shown Clears all data for indicated step select System Optio...

Page 29: ...ell service 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 replace coolant equipment wiring assure...

Page 30: ...ely represents the rms current delivered over the RF cable to the heat station If you have recurring calibration requirements for your EASYHEAT equipment we offer this calibration service return the p...

Page 31: ...Smartburst considers both thermal time constants and self heating in the capacitors to allow higher currents out of the heat station as long as the average value is safe and if the continuous on time...

Page 32: ...How Your EASYHEAT Works 32...

Page 33: ...SYHEAT requires electrical connections at CTB1 and in some cases unit configuration from the touch pad Caution Stored electrical charge can persist at internal terminals for several seconds following...

Page 34: ...mper upper illustration Using 4 20mA source CTB1 1 positive CTB1 2 negative CTB1 1 2 250 resistor included set jumper lower illustration Observe polarity with these connections Setup Control From RPan...

Page 35: ...ulse 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...

Page 36: ...witch will then result in Fault Status signals CTB1 8 13 Case You connect your 24Vdc source and monitoring equipment ex current limited LEDs to remotely track the status of the EASYHEAT Electrical Tou...

Page 37: ...atOn CTB1 12 13 closure Fault No polarity to these connections 1A limit Connect your N C E stop rated 24V 3A min as shown None Result Your remote 24Vdc status signals echo EASYHEAT status LEDs E stop...

Page 38: ...ls available 3 lights Start Stop upper 2 lights Start Stop Power Control lower The 3 light model puts Stop Start and Status indicator in your hand Stop also works from the front panel The 2 light Powe...

Page 39: ...e this wiring or want to operate without the pendant remember this a jumper is required from 4 com to 5 Stop the jumpers shown from 15 System to 16 Source and from 6 FLS to 7 FLS are required To re co...

Page 40: ...t From RPan 2 light model Electrical Touch pad J8 set upper illustration Remote operation Setup Control From RPan Start Type 2button Start From RPan Operating instructions Once you have unpacked the p...

Page 41: ...ance 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 feature of EASYHEAT To en...

Page 42: ...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 selected select to sel...

Page 43: ...other serial communication application enter a connection name such as EASYHEATComm then select COM1 38400 baud must match selection above 8 data bits parity none stop bits 1 flow control NONE click O...

Page 44: ...is turned on before the system will check if the actual present power value falls outside of the minimum or maximum settings ADDED V5 02 display firmware 1 aldelay 10 21 almax Sets the alarm maximum...

Page 45: ...format as crdata 1 chrdata config none Returns the configuration of the power supply including all user settings and heat station settings 1 config crdata none Continuous raw data Same format as rdata...

Page 46: ...IME command See ctime for description 1 slcdata slcrdata none Continuous comma delimited raw data using the same format as rdata Will not scroll The line feed is removed 1 slcrdata slctemp none Return...

Page 47: ...he transmitter to remain in the transmit state all the time This will aid with noise problems that can be caused while the RF is on and the RS485 cable is picking up random noise characters NOTE This...

Page 48: ...VIEW 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 the power supply runs Key...

Page 49: ...act Ambrell to learn more about eVIEW and see for yourself how PC based monitoring can improve your efficiency and productivity 3 3 5 5 T Ta ap p A Ad dj ju us st tm me en nt t I IH HS S o on nl ly y...

Page 50: ...er remove cover AC power LED panel are not lighted use screwdriver to loosen 12 13 see guide set 12 13 as needed tighten 12 13 in the new position replace cover secure with screws replace line cord ch...

Page 51: ...d remove line cord from rear of unit use Philips screwdriver to remove screws securing cover remove cover note location of capacitor with a 5mm hex wrench remove 2 screws securing capacitor remove app...

Page 52: ...e screwdriver to remove wiring cover use wrench unscrew cord grip flex slide flex cover away from heat station at terminal note position of 2 wires see guide above determine new positions with screwdr...

Page 53: ...r of heat station use screwdriver to remove wiring cover use wrench unscrew cord grip flex slide flex cover away from heat station at terminal note position of 2 wires see guide above determine new po...

Page 54: ...Technical Information 54 if persists follow instructions until heating without...

Page 55: ...handle caps use Philips to remove 2 handle screws remove handle remove 2 chassis screws extract assembly from housing with a 5mm hex wrench remove 2 screws securing capacitor remove apply thin coat o...

Page 56: ...flow through caps so tube removal is not necessary remove 2 capacitors copper base plate apply thin coat of thermal paste to mounting surfaces of new caps assure no paste between cap halves install n...

Page 57: ...andle Mounting ref attached dwg Weight no coil 8 3 6 w cable 2 0 9 10 4 5 w cable 2 0 9 lb kg Cable 10 3 0 ft m Bend radius 6 152 in mm min 4 4 2 2 E El le ec ct tr ri ic ca al l Equipment Input Descr...

Page 58: ...y line coil 90 1 refer to 3 for complete transformer settings information 2 using 2 4 turn coil with matched calorimeter Customer output Port Active CTB1 Description Limits Ready closed 8 9 isolated...

Page 59: ...5 5 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...