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PPSTinc 12.5-135/400 User Manual

Induction power supplies lcd display integral heat station
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Induction Power Supplies
12.5KW; 135 – 400 KHz
LCD Display
(Integral Heat Station)
User's Guide
Model 12.5-135/400
05/08
Rev D

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Summary of Contents for PPSTinc 12.5-135/400

  • Page 1 Induction Power Supplies 12.5KW; 135 – 400 KHz LCD Display (Integral Heat Station) User’s Guide Model 12.5-135/400 05/08 Rev D...

  • Page 2: Table Of Contents

    1. Specifications and features..................3 2. Getting started......................6 3. Connections ......................8 4. Front panel description and operation..............10 5. Programming and Status monitor ................. 16 6. Load station tuning....................22 7. APPENDIX A: USER INTERFACE................25 8. Layout.………………………………………………………………………………………27 9.

  • Page 3: Specifications And Features

    1. Specifications and features 1.1. Output Maximum Power 12.5kW Maximum Apparent Power 25kVA @ 240V input Minimum Power Factor 0.5 @ 480V input Duty Cycle 100% Maximum Voltage 500V Power Transformers (6) 2 :1 Frequency Range 135kHz to 400kHz Maximum response time 0.1s Minimum Allowed OFF-Time 0.5s...
  • Page 4 1.4. Front panel controls and indicators LED Indicators Yellow indicator for limit. Red indicators for fault and trip. Red indicator for fault. Yellow and Green indicators for heat on and off. Numeric Displays Run time read-outs for: Job and Step for Programmed mode Elapsed time for heat period power meter (0-100%) LCD Display...
  • Page 5 1.5. Internal heat station Resonant capacitors Mounting space provided for sixteen capacitors. Eight 210nF, 500V or 8 200nF, 700V capacitors supplied. 330nf available Series Parallel Capacitor Rail Kit available (optional) Series inductor Adjustable for load matching 1.6. Protection Limited to 12.5kW in any feedback Power configuration Limited to 250A peak.

  • Page 6: Getting Started

    2. Getting started 2.1. Safety Warnings HIGH FREQUECY RADIATION can interfere with radio navagation, safety services, computers and communication equiptment. Have only qualified person familiar with electronic equiptment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
  • Page 7 2.2. Set-up The following is a list of steps describing the required actions to get the power supply set up. 1. Check for any visual damage that could have happened during shipment. Check all plug-in connectors on PCBs. WARNING: Make sure that the power is locked out before connecting the input power.

  • Page 8: Connections

    3. Connections This section gives a description of the required steps to connect the supply voltage, load, cooling water and remote loader to the unit. 3.1 Three phase input voltage WARNING Make sure that the power is locked out before connecting AC power to the unit.
  • Page 9 Figure 2: Output blocks mounting. 3.3 Cooling water The cooling water can be connected to the left or right side of the power supply. The unit is shipped with the water inputs on the left hand side. Two female ¼” NPT connections are provided.

  • Page 10: Front Panel Description And Operation

    4. Front panel description and operation 4.1 Front panel description This section identifies and describes the various parts of the front panel. Fault, Trip and Limit LEDs LCD display Heat On/Off LEDs Reset button Program Indicator Heat switch Time Indicator Power Knob Power Indicator Program Buttons...
  • Page 11 4.1.1 Fault, Trip and Limit indicators  Identified by --in Figure 3. Fault indicator: This indicator is red in color and is lit if the unit gets any faults. No power is being delivered to the load and the heat OFF indicator will be lit. There are six fault statuses displayed on LCD: ...
  • Page 12 4.1.2. Heat ON/OFF indicators. These LEDs show whether the power supply is generating output or is off. (identified  -- in Figure 3.). 4.1.3. Program status indicator.  Identified by -- in Figure 3. This read-out displays the programs status when using the PROGRAMMED mode.
  • Page 13 4.1.7. Reset button  Identified by -- in Figure 3. This button is used to clear the fault and/or trip indicators if a run-time or interlock trip has occurred. Depressing the button will clear the latch for the fault and trip indicators. If the LED does not go out, then the reason for the fault is still present.

  • Page 14: Programming And Status Monitor

    When Manual is in continuous mode: “MANUAL [CONT]” displays on 1 line of LCD, When Manual is in timed mode: “MANUAL [T=0.0S] displays on 1 line of LCD. 1) Operation in Manual continuous mode. Press START switch to heat on and press STOP switch to heat off. If current mode is in manual timed, you can change the mode by pressing RIGHT (►) key for 1 sec.
  • Page 15 Aux. interlock control  Power control mode  Feedback control mode  2) Job select: Selecting job to proceed under Programmed mode. 3) Job order: Setting Job parameters in each profile. 4) System parameters: Setting control parameters. Power limit  Capacitor voltage limit ...
  • Page 16 EXT HEAT: Selecting External heat control mode.  (only when unit is in “HEAT CONT = EXT” mode. MOMENT: On or off by contact of E- HEAT terminal of TB2 on EXT-TERM  board (close=On, open=Off) LATCH: Latch On or latch off alternately by contact close triggering of E- ...
  • Page 17 3. Press “ESC” key to return to PROGRAM menu without setting change. 5.1.4. Job order Setting job parameters to operate the power supply in “PROGRAMMED” mode. The power supply can be programmed for 15 separate heating profiles or jobs. Each profile can contain up to 29 steps.
  • Page 18 HS TEMP: HS TEMP must be set to 50℃ always. REST W/TEMP: Set the restart-able inlet water temperature as centigrade (0~ SHDN W/TEMP). Power supply can restart after water temperature has gone down to this setting value. This value must be lower then SHDN W/TEMP value (37℃). COMM ADDR: When the RS485 port is being used to control or monitor the power supply, a unique ID for the machine can be entered (1~255).
  • Page 19 CAL: display status of control board calibration. If this shows “FAIL”, it has lost  the calibration data and you need to call Tech Support. 5.2.3. Inverter status No function for this power supply. 5.2.4. Auxiliary status W/IN TEMP: Displays water inlet temperature as centigrade (℃). ...

  • Page 20: Load Station Tuning

    6. Load station tuning. This section describes WARNING: Always ensure that procedures tuning heat both the power supply’s circuit station so that full power will be breakers are turned OFF when obtained at the desired frequency. adjusting heat station components. Initial setup.
  • Page 21 the capacitance has to be halved, and vice versa. The procedure for changing the capacitors is given in section 0 4. Once the frequency is acceptable, turn the power knob to maximum power (fully clockwise).  If the unit is not delivering full power and the frequency is indicated as ~135 kHz (no limit indicator will be lit), the tank frequency is below the range of the unit.
  • Page 22 *Care should be taken to avoid starting the power supply below the full power operating frequency; doing so will cause a current trip. 6.3 Changing the heat station components. This section describes the procedures for changing the heat station components. 6.3.1 Capacitors.
  • Page 23 Figure 4: Changing the capacitors. 6.4 Series inductor. The turn selector bar is identified by  in Figure 5. For the initial setup (section 6.1) this is the only bar that is used and should be screwed onto the correct set of tabs to select the desired number of turns on the series inductor.
  • Page 24 Table 1: Turns bar and shorting bar positions for fine tuning Inductance Decrease   Increase Turns-bar … 6 Shorting-bar … T M B T M B T M B T M B Turn selection bar Twelve turns position Shorting-bar in the bottom (B) position Figure 5: Adjusting the series inductor.

  • Page 25: Appendix A: User Interface

    7. User Interface Terminal block to connect external devices for remote control or monitoring power supply is located on the left lower inside of front door. Terminals for I/O signals. 7.1.1. Analog signal input (TB1)  R+5V: 5V reference: This 5V reference voltage is available for connecting to a potentiometer remotely.
  • Page 26  M-CV: Output voltage monitoring signal (0~5V, 100%=5V).  GND; Common terminal for monitoring signals (ground). 7.2. Terminals for external connect (CN-1) 7.2.1. Input contacts(TB2)  HEAT; Connecting terminal HEAT and terminal COM will start the unit in the external heat control mode. ...

  • Page 27: Finding Dew Point

    Finding dew point using Air Temperature and Relative Humidity in Fº % Relative Humidity Temp °F 110 110 108 105 105 103 100 100...