Ultraflex Easy Melt Air 1G, Operation Manual

Page 1: ...UPT Series Easy Melt Operation Manual Version 1 2 1 www ultraflexpower com Desktop Melter Product Model Easy Melt Air 1G Air cooled Desktop Melter 1kg Gold Part Number 0UPT 016 600 00 Operation Manual ...

Page 2: ...HEDULING 8 1 3 2 PERSONNEL 8 1 3 3 INSPECTION AND MAINTENANCE PROCEDURE 8 2 PRODUCT SPECIFICATIONS AND FEATURES 9 2 1 PRODUCT SPECIFICATIONS 9 2 1 1 OVERVIEW 9 2 1 2 DEVICE SPECIFICATIONS TABLE 9 2 1 3 CONNECTION DIAGRAM 10 2 2 CONTROLS AND OPERATION 11 2 2 1 CONTROL PANEL OVERVIEW 11 2 2 2 CONTROLS AND INDICATORS 11 2 2 3 REGULATION MODES AND SYSTEM STATUSES 12 2 2 4 MENUS AND NAVIGATION 13 2 2 4...

Page 3: ...U AND NOT THIS MANUAL ARE REPONSIBLE FOR ALL SAFETY PRECAUTIONS This manual is for reference purposes only Personnel should be trained on proper operation of this equipment before using Only authorized personnel may perform any troubleshooting or repair on any ULTRAFLEX manufactured equipment Failure to comply will void warranty Please contact the ULTRAFLEX Service Department before servicing any ...

Page 4: ...NO OPERATOR SERVICEABLE PARTS OR ADJUSTMENTS WITHIN THE PRODUCT ENCLOSURE REFER ALL SERVICING TO TRAINED SERVICE TECHNICIAN SOURCE POWER MUST BE REMOVED FROM THE PRODUCT PRIOR TO PERFORMING ANY SERVICING THIS PRODUCT IS DESIGNED FOR USE WITH NOMINAL A C MAINS VOLTAGES INDICATED ON THE RATING NAMEPLATE 1 1 2 2 GROUNDING This product is a Class 1 device which utilizes protective grounding to earth t...

Page 5: ...ng steps Unpacking the equipment Selecting the site where the equipment will be used Connecting the Heat Station if remote Heat Station is provided Connecting accessories or interfacing the system with other controls if necessary Completing the Power and Ground Earth connections POWER AND GROUND EARTH CONNECTIONS MUST BE MADE LAST FAILURE TO DO SO WILL CREATE A HAZARDOUS CONDITION THAT MAY RESULT ...

Page 6: ...sible by the operator Device has to be seated on a mechanically secure surface 1 2 4 COOLING REQUIREMENTS The power transistors and rectifiers in the Power Supply are maintained within their safe operating temperature range by means of forced air cooling fans The fan inlets must be kept clean from obstructions in order to insure proper air circulation If installed in confined spaces care must be t...

Page 7: ... then the system is ready for operation See Section 2 of this Manual for Connections Diagrams 1 2 7 USING THE MACHINE 1 Connect the machine to the electric supply 220 230 VAC single phase 2 Crucible Check that your crucible is good enough to make a melting A too much used crucible can make the casting very slow Check also that the bottom is not too thin you risk that it brakes during the melting c...

Page 8: ...F period with working cooling fans The frequency of any maintenance program is a function of environment degree of equipment use and operator experience 1 3 2 PERSONNEL Qualified personnel must perform inspection and maintenance procedures only Personnel must read and be thoroughly familiar with all safety precautions discussed in this manual 1 3 3 INSPECTION AND MAINTENANCE PROCEDURE The followin...

Page 9: ...f an output matching transformer with fixed transformer ratio air cooled tank capacitor assembly and terminals for connecting the induction coil The unit is digitally controlled through a control panel located on the front panel of device Figure 2 1 Overall Device Dimensions in mm Notes 1 A tool is required to gain access to the Power Supply This is to prevent accidental exposure to the internal h...

Page 10: ...ank Capacitor 1 x 3CFM 105 001 01 UPT 120 200kVA 1 2µF Working Coil with built in thermocouple 1ASM 016 601 00 Di 70mm inner surface with cement Timer Resolution 1min step 1 30 min PROTECTION Over current 45 A Peak Inverter output current Over temperature heat sink 60 C Reset by depressing STOP MISCELLANEOUS Temperature Ranges 32 F 0 C to 104 F 40 C Operating 4 F 20 C to 150 F 65 C Storage Humidit...

Page 11: ...tal parameters and alpha numeric messages providing intuitive and informative visual feedback The users can also navigate through easy to use service diagnostics and setup menus 2 2 2 CONTROLS AND INDICATORS The control panel has the following controls and indicators Figure 2 3 UPT 016 600 00 Control Panel Layout and Controls Table 2 3 Control Panel Components Name Function Description Indicator C...

Page 12: ...r status INDICATOR 7 LED RED output set point power in LED RED Illuminated when Indicator 4 shows output set point power in INDICATOR 8 LED RED LED RED Illuminated when the Thermo regulator is switched ON from System menu Figure 2 6 INDICATOR 9 UP and DOWN arrow buttons UP and DOWN arrow buttons dual function changing value of parameters scrolling through the menus CONTROL 10 SELECT button SELECT ...

Page 13: ...E min TEMP C ALARM HEAT ON Y POWER TIME min TEMP C ALARM HEAT ON POWER TIME min TEMP C ALARM HEAT ON POWER TIME min TEMP C ALARM HEAT ON SELECT 2s Y Thermo Regulator Set Point 1 SELECT 2s N N START Button Y N SELECT 2s N Y N N ERROR N Error Y Y Y N Error ERROR Y Error N System Menu ERROR SELECT 2s System Menu START Button Y HEAT ON Menu HEAT ON Menu HEAT ON Menu Figure 2 4 Main Menu Structure 2 2 ...

Page 14: ...AT ON Menu 1 Y N SELECT 2s Extended Menu ERROR Y Error Y SELECT 2s Y POWER TIME min TEMP C ALARM HEAT ON N SELECT 2s Y POWER TIME min TEMP C ALARM HEAT ON SELECT 2s N Temperature C Main Menu SELECT 2s N N STOPT Button Y ERROR N Y Y N Y N Y Y N N N Error Main Menu 1 Extended Menu 1 ERROR STOPT Button SELECT 2s Extended Menu Main Menu Error Figure 2 5 HEAT ON Menu Structure ...

Page 15: ...R TIME min TEMP C ALARM HEAT ON POWER TIME min TEMP C ALARM HEAT ON N Y Y POWER TIME min TEMP C ALARM HEAT ON SELECT 2s Control Board SW Revision POWER TIME min TEMP C ALARM HEAT ON SELECT 2s N Y Y SELECT 2s N Y N N Down Button Y POWER TIME min TEMP C ALARM HEAT ON 3 4 Thermo Regulator ON POWER TIME min TEMP C ALARM HEAT ON N 3 Doun Button POWER TIME min TEMP C ALARM HEAT ON SELECT 2s Y Thermo Reg...

Page 16: ...HEAT ON SELECT 2s Water Flow L min POWER TIME min TEMP C ALARM HEAT ON Y SELECT 2s N Y N Down Button Y 2 N N Figure 2 6 SYSTEM Menu Structure 2 2 4 4 EXTENDED MENU Navigation EXTENDED MENU is accessible from Heat ON Menu by pressing SELECT button for 2 seconds It is shown on Figure 2 7 This menu allows additional basic inverter parameters to be shown power current voltage frequency ...

Page 17: ...CT 2s N N N SELECT 2s ERROR Y Error Y POWER TIME min TEMP C ALARM HEAT ON STOP Button Y 1 Main Menu ERROR N STOP Button Y Y Main Menu Error N POWER TIME min TEMP C ALARM HEAT ON Y OUTPUT VOLTAGE OUTPUT POWER OUTPUT CURRENT SELECT 2s N N ERROR Y Error Y POWER TIME min TEMP C ALARM HEAT ON STOP Button Y 1 Main Menu FREQUENCY N N 5 6 ...

Page 18: ...WER TIME min TEMP C ALARM HEAT ON Y Power Set Point SELECT 2s N N ERROR Y Error Y POWER TIME min TEMP C ALARM HEAT ON STOP Button Y 1 Main Menu TIMER N SELECT 2s ERROR N STOP Button Y Y Main Menu Error N POWER TIME min TEMP C ALARM HEAT ON Y TEMPERATURE N N ERROR Y Error STOP Button Y 1 Main Menu N Figure 2 7 EXTENDED Menu Structure ...

Page 19: ...uple mounted Thermo regulator is switched OFF see Fig 2 6 and operator has to watch crucible temperature Note When thermo regulator is switched OFF the parameter TEMPERATURE is invisible on the 7 segment LED display 3 TUNING AND TROUBLESHOOTING 3 1 LOAD TUNING GUIDE Because of fixed tank circuit and load graphite crucible device is factory tuned and doesn t need additional load tuning 3 2 SERVICE ...

Page 20: ...rds Er05 Auto Tune Failed The resonant frequency is not found The unit could not find resonant frequency during auto sweep Check resonant loop parameters and adjust if needed load coil inductance tank capacitors value Er09 Communicatio n Fault Communication Error Between Panel and Control Board No acknowledgement is received after the last command Check cables and RS connectors between boards Er21...

Page 21: ...ncluding load ambient temperature at the time of the failure 5 Detailed description of the actions taken 6 Approximate time in service If our technical staff is unable to help you over the phone then a repair authorization number RA will be issued for you With this number enclosed in you return package you can ship the unit back for repair or request a service engineer to repair the unit on site 3...

Page 22: ...10 1 5 Tank Capacitor UPT 120 200kVA 1 2µF 3CFM 105 001 01 1 6 Inductor Choke 5MIT 471 001 00 1 7 Single Power Supply 60W 12V 3PSP 000 018 01 1 Appendix B ACCESSORIES Table Appendix B Accessories Table Part Number Description Qty 1 1 kg gold Graphite Crucible 2DET 016 000 KS 1 2 Cover Crucible 2DET 016 000 HI 1 3 Crucible tongs 4HVM 000 102 00 1 4 External Thermocouple option 1ACC 016 270 00 1 Opt...