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Rimac DHI3-F1 Operating And Maintenance Manual

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INDUCTION HEATER
DHI3-F1
Operating and Maintenance Manual, v1.4.01

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  • Page 1 INDUCTION HEATER DHI3-F1 Operating and Maintenance Manual, v1.4.01...

  • Page 3: Table Of Contents

    ONTENTS INTRODUCTION..........................8 SAFETY INSTRUCTIONS ........................9 GENERAL RULES WHEN USING DHI3-F1 ..................9 INFORMATION SYMBOLS ......................11 SYMBOLS INDICATING HEALTH RISKS ..................13 2.3.1 ELECTRIC SHOCK ......................13 2.3.2 CAUTION! HOT SURFACE ....................14 2.3.3 RISK OF FIRE ........................14 SYMBOLS WARNING WHILE HANDLING THE DEVICE ............15 2.4.1...
  • Page 4 ABOUT THE DEVICE AND HEATING .................... 24 ......................24 UPPORTED TECHNOLOGIES 7.1.1 DHCS3 - Dawell Heating Control System 3 ..............24 Technology developed by Dawell enabling controlled heating with multiple-pass real-time control of various parameters, which is the heart of the device features. The heating can thus be controlled in various modes, increasing its applicability and versatility.
  • Page 5 7.2.3 Control to desired temperature (CT, optional) ............27 ......................... 27 ONTROLLED HEATING 7.3.1 Using the heating timer ....................27 7.3.2 Controlled heating based on set temperature profile ..........27 ..........27 EMOTE CONTROL AND INTEGRATION INTO PRODUCTION PROCESSES DEVICE CONTROLS ........................29 ..................
  • Page 6 8.6.7 Input voltage ......................... 39 8.6.8 Cooling temperature ....................39 8.6.9 Limitation ........................39 8.6.10 Errors ........................... 40 ............................40 ETTING 8.7.1 “HC” Heating mode ...................... 42 8.7.2 “Po L” Maximum output power ..................42 8.7.3 “ic.L” Power line current limit ..................42 8.7.4 “FIL”...
  • Page 7 10.1 ........................49 UPPORTED FEATURES CERTIFICATES ..........................50 USED DEVICE DISPOSAL ......................51 WIRING DIAGRAM ........................52 QUALITY CERTIFICATE ......................... 53 WARRANTY SERVICING ......................54 WARRANTY CERTIFICATE ......................55...

  • Page 8: Introduction

    NTRODUCTION Dear Customer, thank you for your trust and purchase of our product. Before commissioning, please read carefully all the instructions contained in this Manual. Instructions for use and maintenance shown herein have to be strictly observed for optimum and lasting use. We recommend, in your own interest, committing maintenance and any repairs to our servicing organisation, since it has available the appropriate tools and specially trained staff.

  • Page 9: Safety Instructions

    Symbols shown in this Manual warn and identify potential hazards when handling the device. Do not leave DHI3-F1 unattended while it is turned on. Always deactivate DHI3- F1 with the master switch when not using it for heating! Make sure that the power supply unit and the grip have sufficient air supply for cooling.
  • Page 10 If the socket voltage does not match that shown on the type plate, it can result in a serious hazard and damage to your DHI3-F1. Do not exceed the working cycle of the DHI3-F1, being 1-2 minutes heating (on) and 2 minutes cooling (off).

  • Page 11: Information Symbols

    IMPORTANT! Read this Manual carefully to gain information about the device features. Inappropriate handling may cause injuries to persons and damage to the device. 2.2 INFORMATION SYMBOLS The symbols shown below will guide you through this Manual and warn you of potential risks.
  • Page 12 CAUTION! Hot surface! Risk of burns! CAUTION! Risk of electric shock! Risk of fire Electromagnetic field risk Do not use cardiac pacemakers, implanted devices and watches or other metal objects.

  • Page 13: Symbols Indicating Health Risks

    Always use! Protective goggles, protective masks and protective gloves 2.3 SYMBOLS INDICATING HEALTH RISKS 2.3.1 ELECTRIC SHOCK CAUTION! Never remove casing and do any activity with the induction heater unless you have first disconnected the plug from the socket. Then wait at least 1-2 minutes after unplugging it.

  • Page 14: Caution! Hot Surface

    2.3.2 CAUTION! HOT SURFACE CAUTION! Do not touch any objects located near the induction heater unless you have checked that it has cooled down. Do not touch the induction coil if it is activated and the strong magnetic field and heating are turned on. ALWAYS wear protective gloves or other protections when handling the device as there is a risk of burns.

  • Page 15: Symbols Warning While Handling The Device

    2.4 SYMBOLS WARNING WHILE HANDLING THE DEVICE 2.4.1 SAFETY EQUIPMENT WHEN WORKING WITH THE DEVICE Always wear protective goggles or face mask when using the DHI3-F1.

  • Page 16: Electromagnetic Effects

    These exhausts may be toxic. Always use adequate protective masks or respirators. Always use protective gloves with adequate thermal resistance when working with the device. The high temperatures produced by using the DHI3-F1 may cause serious burns on contact with the heated part. 2.4.2 ELECTROMAGNETIC EFFECTS The electromagnetic field (EMF) may affect implanted medical devices.
  • Page 17 Persons with other metallic or electronic surgical implants are not allowed to work with the DHI3-F1 and have to keep a safe distance of at least 1 m from the device. When working with the DHI3-F1, do not wear any metal objects such as...

  • Page 18: Periodic Inspection And Maintenance

    3 PERIODIC INSPECTION AND MAINTENANCE Scheduling device maintenance has to consider the degree and circumstances of device use. Considerate use and preventive maintenance help prevent needless defects and malfunctions. Perform checks as per standards and law in force. Only workers with adequate electrical engineering qualifications may carry out any jobs on the device.

  • Page 19: Storage

    4 STORAGE The device has to be stored in a clean and dry room. Protect the device from rain and direct sunshine. After heating completion, leave the device switched on for 10 more minutes - it will be cooled down by fans until it is cold, then it deactivates the fans. After that, turn it off using the master switch and disconnect it from the power line.

  • Page 20: Warranty Provision

    5 WARRANTY PROVISION Unless otherwise specified, the warranty period for devices is set by the manufacturer at 12 months from the date of sale to the buyer. When making a claim for warranty repair, the warranty certificate has to be shown; it is only valid if it bears the date of sale, serial number, stamp of the shop and the seller’s signature, confirming proper demonstration and explanation of the device features.
  • Page 21 Manual, using the device for purposes for which it is not intended, and overloading the device, albeit temporarily. The warranty expires if the user makes any unpermitted modifications or changes to the device, connects the device wrongly, or has used the device in contravention of technical requirements.

  • Page 22: Commissioning

    OMMISSIONING 6.1 Unpacking and first start 1) Unpack the device and any accessories supplied and check that they are in good order and the device and the accessories are not damaged. If you find any defects, do not continue! 2) If the focusing head is not attached to the grip by default, screw it on. 3) Fill the device with the coolant supplied with the device via the filling hole.
  • Page 23 The device has integrated coolant level inspection. In case the coolant runs out, the device stops heating and displays the error message “E##”. In that case, refill the coolant in the tank as described above.
  • Page 24 BOUT THE DEVICE AND HEATING 7.1 Supported technologies 7.1.1 DHCS3 - Dawell Heating Control System 3 Technology developed by Dawell enabling controlled heating with multiple-pass real- time control of various parameters, which is the heart of the device features. The heating can thus be controlled in various modes, increasing its applicability and versatility.
  • Page 25 7.1.5 URC - Universal Remote Control Support to universal remote device control, both analog and digital, or using a data bus, enabling easy integration into production processes. 7.1.6 ACMS - Automatic Check And Monitor System Combines features that check and verify device functionality and condition after activation, and a feature that constantly supervises and monitors the heating running and parameters for maximum device safety and reliability.
  • Page 26 Another advantage is that moving the burner away does not increase the power output and resulting needless device overheating, and increases the maximum continuous heating time and saves energy. Advantages:  power control by moving nearer or further  fine heating ...

  • Page 27: Control To Desired Temperature (Ct, Optional)

     The disadvantage is the great increase in the induction output when moved away from the material or with inappropriately chosen coil, resulting in high heating load and quick temperature increase, reducing in turn the load factor and rapidly overheating the device.
  • Page 28 and current coil, and provides logical outputs informing about the system status. In the highest class, it support full control via a digital data bus, enabling both full control and complete system monitoring.

  • Page 29: Device Controls

    EVICE CONTROLS 8.1 Description of device components...

  • Page 30: Heating Indicator Lamp

    8.1.1 Heating indicator lamp Indicates heating status. Indicator lamp Status  green heating in progress  yellow warning – limited heating output  heating error – overloading  red, flashing heating error – wrong coil 8.1.2 Cooling and overheating indicator lamp Indicator lamp Status ...

  • Page 31: Remote Indicator Lamp

    8.1.3 REMOTE indicator lamp Indicator lamp Status  green remote control activated 8.1.4 8.2 Activating the device  Check the coolant level and refill if necessary.  Connect the device to a socket and turn it on using the switch at the back of the device.
  • Page 32  Controlled power mode (CP), indicator lamp glows red – the user sets the desired  heating power in % of maximum heating power and the device automatically adjusts the required parameters to maintain the set power.  Controlled magnetic field mode (CF), indicator lamp glows green ...

  • Page 33: Heating Timer

     green, flashing power reading in kW during the heating  yellow heating temperature setting in %, mode CT  yellow flashing temperature reading in °C during the heating 8.4 Heating timer The timer makes it possible to automatically stop heating after a set amount of time, enabling accurate dosing of energy (heat) introduced to the material, e.g., for spot or repeated heating to a set temperature.

  • Page 34: Program

    Indicator lamp Status  heating time settings  green timer active – heating in progress  green, timer active – timeout flashing 8.5 Program The program enables setting the heating profile. It contains 3 sections, with power and time settings for each (separately for each mode CP/CF/CT). Power can be set from a minimum to a maximum, or ENC, which is power set by the encoder.
  • Page 35 Program ---,1 to 9 Mod (or current mode) CP/CF/CT Enc / Min-Max % Power, section 1 OFF / 1-600s Time, section 1 Enc / Min-Max % Power, section 2 OFF / 1-600s Time, section 1 Enc / Min-Max % Power, section 3 OFF / 1-600s Time, section 3 If you wish to exit the PROGRAM display and continue to further settings, select “---”...

  • Page 36: Info

     green timer active – heating in progress  green, timer active – timeout flashing 8.6 Info Info enables display of basic information about the heating process and the device. It thus facilitates selection or optimisation of induction coils for the material to be heated, removal of any problems, etc.
  • Page 37 The following parameters are available in Info: Description Display Value Unit Return / exit Power transmitted 0.01 kW Output power 0.01 kVA Power factor Frequency 0.1 kHz Input current 0.1A Output current 0.1A Input voltage Vrms Cooling 0.1°C temperature Limitation --- = no limitation po = max.

  • Page 38: P - Power Transmitted

    8.6.1 P – Power transmitted Shows the current device power output in Watt, which approximately (after deducting loss in cable and heating head) matches the power or energy introduced to the material being heated. It is thus a parameter directly related to heating speed and temperature. This transmitted power increases with growing bond (decreasing gap) between the heating coil and the material.

  • Page 39: Frequency „Fre

    the more efficient the heating. The recommended gap is approx. 2-5 mm. With smaller gaps, heat from the material being heated is transmitted into the coil, resulting in a faster device overheating. 8.6.4 Frequency „FrE“ The current heating frequency, which should be within 25-40 kHz with a correctly selected coil, depending on the load and the material being heated.

  • Page 40: Errors

    input to, say 10A, the device reports that the power is limited by the input current. If heating proceeds correctly and in the optimum band, the device will always display “---”, meaning that the device is not limited by anything. The heating is limited: ...
  • Page 41 confirm the setting; this will return you to selection of another parameter, or select “---” to go to the next setting. To exit to power settings immediately, press and hold down the encoder. The indicator lamp has to following statuses: Indicator lamp Status ...

  • Page 42: Hc" Heating Mode

    Water Fill yes = activates filling and venting Factory setting YES = load factory setting Unlock code servicing menu code, to unlock features ... Firmware Display firmware version 8.7.1 “HC” Heating mode Enables selection of desired heating mode – see Heating modes XXX. The following options are available: ...

  • Page 43: Fil" Coolant Filling And Venting

    8.7.4 “FIL” Coolant filling and venting Used for manual activation of venting and coolant filling. 8.7.5 “CoL” Cooling settings Used for selecting the preferred cooling mode. The following options are available:  Lo – silent mode, where the user prefers quieter cooling and does not mind higher grip temperature.

  • Page 44: Firmware

    8.7.8 Firmware Displays the current device firmware version. 8.7.9 Unlock code Allows unlocking some device settings and features by entering a code.

  • Page 45: Remote Control

    EMOTE ONTROL Activates remove device control via an RMT connector. Signal Type Description INPUT Analog control signal OUT ERROR OC / DIG closed on error OUT HEATING OC / DIG closed during active heating Note: The output signals are not active if DIG remote control is used. 9.1.1 Connector pinning Analog IO...

  • Page 46: Foot Pedal Connection

    *CAN-B 9.1.2 Foot pedal connection Switch between pins 1-2; 10k potentiometer between 1-2; 9.1.3 Control connection ON/OFF 9.1.4 Analog remote control connection 9.1.5 Digital remote control connection 9.1.6 USB connection 9.2 List of error messages Error Description Undervoltage Overvoltage Input overcurrent Output overcurrent Overload Frequency –...
  • Page 47 20-256 Device servicing errors...

  • Page 48: Technical Parameters

    10 T ECHNICAL PARAMETERS DHI44F DHI45F DHI45C/46C Power requirement [V] 230 (180-265) Frequency [Hz] 50/60 Power consumption, I1max 16.5 Input current limiter, I1lim 6 – 16 6 – 16.5 Encapsulation IP21 Okomentoval(a): [CO1]: Co tak vím, klasifikace krytí Working frequency 18 –...

  • Page 49: Supported Features

    Power with open coils Induction head small small medium Price Weight Power factor Intended for light servicing, universal, heavy loads focus focus open coils 10.1 Supported features...

  • Page 50: Certificates

    11 C ERTIFICATES Applied standards pursuant to GR no. 118/2016 and 117/2016 Coll.: pursuant to Directive 2014/35/EU (Low voltage): pursuant to Directive 2014/35/EU (Low voltage):  ČSN EN 60519-1 ed. 4 : 2015 (IEC 60519-1:2015)  ČSN EN 60519-3 ed. 2 : 2006 (IEC 60519-3:2005) pursuant to Directive 2014/30/EU (Electromagnetic compatibility): pursuant to Directive 2014/30/EU (Electromagnetic compatibility): ...

  • Page 51: Used Device Disposal

    USED DEVICE DISPOSAL These devices are built using materials that contain no toxic substances or poisonous to the user. Dispose of the discarded device using a collection point intended for collection of used electric equipment. Do not dispose of the used device as ordinary waste.

  • Page 52: Wiring Diagram

    13 WIRING DIAGRAM...

  • Page 53: Quality Certificate

    14 QUALITY CERTIFICATE The Quality Certificate is supplied with the device as a separate certificate.

  • Page 54: Warranty Servicing

    15 WARRANTY SERVICING Warranty servicing may only be done by servicing technicians trained and authorised by the Manufacturer. Before making a warranty repair, check the device data: date of sale, serial number, device type. If the data are not in accordance with the requirements for granting warranty repair, such as expired warranty period, wrong device use in contravention of the instructions for use, etc., the repair is not a warranty repair.

  • Page 55: Warranty Certificate

    16 WARRANTY CERTIFICATE Date of sale: ___________________________________________________________________ Seller’s signature and stamp: _____________________________________________________ Record of servicing intervention made Date of acceptance Employee’s Date of repair Claim report number for servicing signature...
  • Page 56 Notes:...

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