Ambrell EasyHeat 0112 Nota di rilascio

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

Revisions:

Rev D was written to:

•Update RS485 command set

Rev E (ECN1308-06) was written to:

•Update back panel figures

•Correct Serial Port enabling via 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

Ambrell B.V.

The Netherlands

+31 (0) 880 150 100

Ambrell SARL

France

+33 970 440 335

801-9309.doc

Table of Contents

1Introduction .....................................................................................................................5

1.1 Safety Considerations ..................................................................................................6

1.2 Front Panel ..................................................................................................................7

1.3 Rear Panel ...................................................................................................................8

1.4 Assembly.....................................................................................................................9

2How Your EASYHEAT Works.....................................................................................13

2.1 Home Zone................................................................................................................14

2.2 Control Zone .............................................................................................................20

2.3 Detailed EASYHEAT Operation ...............................................................................25

2.4 Equipment Maintenance ............................................................................................29

2.5 Calibration.................................................................................................................30

2.6 Smartburst Technology..............................................................................................31

3Customizing 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 Adjustment (IHS only)........................................................................................49

3.6 Cap Replacement (IHS only) .....................................................................................51

3.7 Tap Adjustment; 1-Cap RHS .....................................................................................52

3.8 Tap Adjustment; 2-Cap RHS .....................................................................................53

3.9 Cap Replacement; 1-Cap RHS ...................................................................................55

3.10 Cap Replacement; 2-Cap RHS ...................................................................................56

4Technical Information ...................................................................................................57

4.1 Mechanical ................................................................................................................57

4.2 Electrical ...................................................................................................................57

4.3 Environmental ...........................................................................................................58

5Theory of Coil Design ....................................................................................................59

Notes:

In this manual, these 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 requires your

special attention due to

potential hazards to

personnel or property

EASYHEAT (RHS) Free Front with remote heat station

EASYHEAT (IHS) with internal heat station

EASYHEAT (RHS) with remote heat station

Introduction 5

801-9309.doc

Your EASYHEAT is a solid-state induction heating system that converts single-phase

line voltage to a 1.2kW or 2.4kW terminal output over a range of radio frequencies (RF)

and voltages. This energy is delivered to a series-resonant circuit - including your coil -

where a precisely controlled magnetic field is created around your work-piece.

EASYHEAT uses a special sensing technology enabling greater control of your process;

precise frequency registration under varying load conditions results in increased precision

in heat control and times-to-temp.

Special features

Your EASYHEAT simplifies and improves your heating results with:

•Touch-pad interface for control and programming

•Backlit LCD simultaneous display of up to four data fields

•electrically isolated remote water-cooled heat station

•routine internal access not required, 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 the rear panel

•from one of four 5-step profiles you specify

This selection is made from the touch-pad and can be changed at any time.

Unpacking

Your EASYHEAT induction heating system has been carefully packed to arrive at your

facility in good condition.

We suggest you inspect the shipping carton in the presence of the carrier when the unit

arrives at your facility. Look for dents, crushed corners or torn cartons.

YOU MUST REPORT ALL DAMAGE DIRECTLY TO THE CARRIER.

Check to see that all the parts we shipped arrived at your plant:

•EASYHEAT power supply

•line cord

•remote heat station with cable (RHS models)

•reference coil, complete with locking compression fittings

If you note damage, do not discard any of the exterior packing cartons; retain the

carton(s) so that the carrier's claim agent may inspect it. We will assist you in filing a

claim against the carrier should it be necessary to do so.

Introduction

Your EASYHEAT uses RF energy to raise the temperature of your work-piece. Most of

this RF energy is transmitted into the work-piece and some is transmitted into the air.

Physical Risks

During the HeatOn cycle, high RF voltages are present at your work-coil. There are

several risks, which we instruct you to protect against:

Safety Circuits

Your optional normally-closed E-stop switch can be installed in series with the system

24Vdc supply (CTB1:15-16); when the switch opens, all output power and operations

cease. When the switch is re-closed, the power supply returns to Ready (non-hazardous

state). Your E-stop switch must be isolated (dry-contact), capable 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 personal contact with the work-piece you

are heating. Severe burns can result from contact at these temperatures! The

mounting frame on the bottom can heat during normal use, mount work-head to non-

flammable surface, and do not touch until cooled.

•RF Voltages: we recommend that you provide protection against personal contact

with the work-coil when it is energized (Heat On).

•Induction burns: the energized work-coil causes nearby metals to become heated;

DO NOT APPROACH ENERGIZED WORK-COIL WHILE WEARING OR

CARRYING METAL OBJECTS!

•Electric and magnetic fields (EMF): EMF can affect Implanted Medical Devices.

Implanted Medical Device wearers should consult their doctor and the device

manufacturer before going near induction heating operations.

Introduction 7

801-9309.doc

(RHS) Hoses & RF Cables

The remote heat station attaches here. A circular plastic connector conveys

RF energy to the cable and heat station; plastic tubing routes cooling water

to and from the heat station. Free-Front configuration (right) co-locates all

utilities at the rear of your power supply.

IHS Models

The coil used to apply RF energy to your part attaches here. Compression fittings for ¼”

tubing are provided. A coil kit is supplied with some orders.

Touch-pad & Display

•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/STOP buttons enable front panel control of heating

•navigation buttons are used to program and control the unit

Hoses and RF Cable

Handles Status

Navigation

START/STOP

Display AC indicator

Handles

Coil and terminal

Status

Navigation

START/STOP

Display

AC indicator

Introduction

Water connections (A)

Your EASYHEAT uses circulating water to cool internal components and the coil; inlet

and outlet connections for the entire system are made at the rear. Internal flow-switches

are used to interrupt heating operations if this flow is inadequate. Temperature sensors

are used to reduce heating if the internal temperature rises too high

Terminal block (CTB1) (B)

Electrical connections are made here for all 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 connection to the power supply. It includes a 15A

circuit breaker and an EMI line filter. IEC 60320 receptacle accepts a modular line cord

assembly (included).

Line cord entry (D)

The included 8’ line cord attaches here. As an additional safety measure, you must

disconnect the line cord here in order to remove the cover to service the unit.

RJ45 connection (E)

To facilitate serial communications.

RF cable connection (F)

RF cable from the remote heat station (RHS) plugs into this receptacle.

Introduction 9

801-9309.doc

Take these factors into consideration as you determine where to install your system:

•availability of water and drain

•availability of AC power outlet

Attach heat station (if not attached)

unscrew protective cap

insert indexed heat station plug

tighten ring nut

insert RED tubing fully into bottom port

insert clear tubing fully into top port

…to remove tubing

use small slotted driver; pry off collets

push in on retaining rings, pull out tubes

replace collets

Work-coil or reference coil (included with the unit)

Reference coil is included to assure basic operation; suitable for use in heating

remove two nut/ferrule assemblies 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 that coil is aligned to your needs

(vertical, horizontal, etc.)

use 5/8” wrench to hold the bulkhead nut

use 9/16” wrench to tighten (clockwise) two

compression nuts to the unit

Work-coil (your construction)

wind your coil allowing 2” equal-length leads

(min) for connection to the equipment

trim and de-bur each lead

to each lead, apply one (diagram)

nut

rear ferrule

front ferrule

fully insert both leads into the equipment bulkhead

use 5/8” wrench to hold the bulkhead nut

use 9/16” wrench to tighten each coil nut

Swagelokspares: Nut B-402-1; front ferule B-403-1;

rear ferrule B-404-1

1/4" tube

your coil

nut

rear ferrule

front ferrule

for Free-Front models: same procedure - at rear

Introduction

Rack/panel Mounting

Your EASYHEAT is mountable in your panel or 19” rack (3U); observe these steps and

requirements:

unscrew/remove 4 rubber feet on unit base

(panel) provide cutout and mounting pattern per above; plan for M5 or M6 screws

ensure that rear of unit is supported when mounted

provide at least 17” depth to permit water and AC cordage bend

secure unit with M5 or M6 hardware

Cooling water

In the process of heating your work-piece, the current flowing in the heat station and

power supply heats components, too. It is necessary to dispose of this excess heat to

prevent damage to the components.

EASYHEAT provides a means of directing fresh water into and through the components,

enabling 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 distilled water

•Do not use de-ionizing water systems

•Do not use inhibited glycols as anti-rust or anti-freeze agents

•(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 use ferrous pipe for this system; it can lead to equipment damage!

Establish a cooling water source capable of 40psi differential pressure across the

system and at least 0.7 g/m (2.6 l/m) flow

Provide inlet and outlet water through ¼” copper or plastic tubing

Cut each tube end cleanly and remove any burrs

Insert supply tube end fully into fixture labeled INLET

1.5 (38)

18.3 (465)

2.25 (57)

17.5 (445)

5.2 (132)

Not to scale; inch (mm)panel cutout

Questo manuale è adatto per i seguenti modelli

Indice

Altri manuali Ambrell Sistema di riscaldamento

Ambrell

Ambrell 3542 Manuale utente

Manuali Sistema di riscaldamento popolari di altre marche

aerauliqa

aerauliqa QR350ABP Manuale utente

WatchGas

WatchGas ATEX BEACON Manuale utente

Viessmann

Viessmann Vitoligno 300-H Istruzioni operative

Lampoassa

Lampoassa 203GT Manuale utente

MSA

MSA SOA-1022 Manuale utente

nilan

nilan Compact P Manuale utente

ITR

ITR OASIS NE-S Manuale utente

Carrier

Carrier 48LJD Dimensioni e guida di installazione

aldes

aldes EVEREST XV Manuale utente

Kober

Kober C22SPV23MEF Manuale utente

Oxygen

Oxygen X-Air V400 Manuale utente

Carrier

Carrier FB4CNF Manuale utente

Kroll

Kroll HM200 Manuale

Kroll

Kroll HM200 Manuale

NuAire

NuAire XBOXER XBC Series Manuale utente

Trane

Trane VR104GD-U Series Manuale utente

Vents

Vents VUT V mini Manuale utente

Viessmann

Viessmann Divicon Manuale utente