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Ambrell 3542 Manual

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INDUCTION HEATING EQUIPMENT
4.2kW – 10kW Induction Heating Systems
LI Models 3542, 4048, 5060, 7590, 8310
File Name
801-9526-00.doc
Part Number
801-9526
Revision
P
ECN#
1501-33
By
S. Nelson
Approved
Date
01/19/2015
PRECISION
OPERATION AND
MAINTENANCE INSTRUCTIONS

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  • Page 1 PRECISION INDUCTION HEATING EQUIPMENT OPERATION AND MAINTENANCE INSTRUCTIONS 4.2kW – 10kW Induction Heating Systems LI Models 3542, 4048, 5060, 7590, 8310 File Name 801-9526-00.doc Part Number 801-9526 Revision ECN# 1501-33 S. Nelson Approved Date 01/19/2015...
  • Page 2  Rev M: Added SmartBurst content. Added Regulation, Efficiency and Power Measurement content.  Rev N: Added WEEE disclaimer content  Rev P: Added electrical warning to p68. Corrected contact information. Ambrell Companies Ambrell B.V. Ambrell Ambrell Ltd. Ambrell Sàrl nl.ambrell.com...

  • Page 3: Table Of Contents

    MBRELL Precision Induction Heating 801-9526-00.doc Table of Contents Introduction ..........................5     Safety Considerations ......................6     Front and Rear Panels .......................8     Work Head ........................10     Assembly .........................11     Installation ........................14     How Your EASYHEAT Works ..................17  ...
  • Page 4 MBRELL ® Precision Induction Heating 801-9526-00.doc 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...

  • Page 5: Introduction

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

  • Page 6: Safety Considerations

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc 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. Your E uses RF energy to raise the temperature of your work-piece.
  • Page 7 MBRELL Precision Induction Heating 801-9526-00.doc Safety Circuits Your optional normally-closed E-stop switch can be connected to the rear terminal block; when the switch opens, output power is hardware-stopped. 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 0.1A @24Vdc.

  • Page 8: Front And Rear Panels

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Handles Display Status AC indicator START/STOP Navigation Touch-pad & Display All user-interface is conducted here  Status LEDs indicate what your E is doing  AC indicator is lighted when unit is turned on ...
  • Page 9 MBRELL Precision Induction Heating 801-9526-00.doc RF Output, terminals (cover removed) Terminals Circuit Breaker AC Line Inlet System Water Work Head Water Signal Stud Safety Stud RF Output, Water The remote work head attaches here. A specially-designed cable conveys RF energy to the work head while plastic tubing routes cooling water to the coil (CLEAR), to the capacitors (BLUE) and from (RED) the entire work head.

  • Page 10: Work Head

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc The energy generated by the power supply is converted at the work head to a form you can use. The work head is comprised of an enclosure, a transformer, capacitor(s), coil (sample coil shown) and required wiring. See §3 for instructions to change your transformer tap settings.

  • Page 11: Assembly

    MBRELL Precision Induction Heating 801-9526-00.doc Take these factors into consideration as you determine where to install your system:  availability of water and drain  availability of 3 AC power Attach work head & water   remove RF cover (dotted) ...
  • Page 12 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Work-coil or reference coil (included with the unit) A reference coil is included with your work head to ensure basic operation; while it is suitable for use in heating, another coil may have been ordered for your use. If you are attaching your own coil: ...
  • Page 13 MBRELL Precision Induction Heating 801-9526-00.doc Cooling water In the process of heating your work-piece, the current flowing in the work head and power supply heats components, too. E 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 a drain or to a heat exchanger which will then be recycled back to the equipment.

  • Page 14: Installation

    Failure to connect earth (safety) ground will result in a potentially hazardous condition. Do not omit this step! Mains service We recommend that you install a fused disconnect switch (not supplied by Ambrell) in the branch circuit supplying the equipment. Base your selection of fuses on the equipment nameplate data.
  • Page 15 MBRELL Precision Induction Heating 801-9526-00.doc Start-up display You are ready to apply power to the E  turn on water to your system  turn on fused disconnect supplying your system  turn on circuit breaker at rear of E ...

  • Page 17: How Your Easyheat Works

    MBRELL Precision Induction Heating 801-9526-00.doc When you turn HeatOn, (details, next page) this equipment concentrates an electromagnetic field within the coil diameter. When you put your metal part into the coil, this field causes internal electric currents to circulate in your part. Friction from these currents heats your part.

  • Page 18: Home Zone

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc operates in the Home zone (illustration). Within this When you turn it on, E zone, you can adjust output levels, set the timer and turn RF power on and off: Status LEDs Home Zone Display indicate what your E is doing: READY: waiting to heat;...
  • Page 19 MBRELL Precision Induction Heating 801-9526-00.doc Do this... Observe...  open water-valve for the system check drain; ensure water is flowing  check the work-coil ensure there is no work-piece yet  check condition of (any) safety all safety devices are clear, electrically barriers or limit switches closed ...
  • Page 20 Sometimes, you may see that the output frequency approaches either end of the operation range of EASYHEAT and the display advises you to increase or decrease capacitance. Please call your Ambrell office for assistance should this happen and we will supply you with the appropriate capacitors.
  • Page 21 MBRELL Precision Induction Heating 801-9526-00.doc Status LEDs This guide will help you understand the operation of your E LED Status and system notices are relevant if your part is in the coil during HeatOn. Status and notices displayed after you remove your part can be ignored Ready is waiting to heat;...
  • Page 22 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Touch-panel features START/STOP When starting the unit from the front panel, use these buttons to (de)activate heating. Press START to begin induction heating. HeatOn (LED) shines and the display is updated with operating data. START operates only within HOME zone Press STOP to halt induction heating (2-button start type, below).
  • Page 23 MBRELL Precision Induction Heating 801-9526-00.doc Navigation This map will help you understand operation and programming your E Each touch-pad button is represented in the map, showing the effect touching each one has depending on your location in the map Amps/ Setpoint Timer Watts...

  • Page 24: Control Zone

    We have configured this for your model and mains AC VOltage level; do not change! If you must connect to another ►440-520 VAC voltage range, see §3.6 or contact Ambrell Service. 230 V models: 187-230 | 230-264 440 V models: 370-440 | 440-520 Auxiliary Out...
  • Page 25 MBRELL Precision Induction Heating 801-9526-00.doc RS485 Baud rate Use  to select baud rate to be used for 38400: RS485 Baud rate communications ►38400 RS485 Address : Use  to select and ▼/▲ to adjust address.  to RS485 Address save.
  • Page 26 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Display Percent To enable/disable use of % displaying output Display Percent levels ►Disable Disable: display A/W Enable: display A/W as a % of maximum Start Type To change START type Start Type 2button: HeatOn when START is pulsed (or ►2 Button CTB1 signal is closed) and remains on when released.
  • Page 27 MBRELL Precision Induction Heating 801-9526-00.doc ► ► ► ► Menu Selection     ►System Status ► ►  (Once this screen is displayed, press ; use ▲/▼ to select operating features): Display the temperature of active components HS65 F AM72 F on the heat sink (HS) and the internal ambient Increase Tap...
  • Page 28 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc ► ► ► ► Menu Selection     ►Heat Station ► ►  (Once this screen is displayed, press ; use ▲/▼ to select operating features): Heat Station This enables the power supply to operate after Choose Menu you make changes to the work head ►Modify Tap...

  • Page 29: Detailed Easyheat Operation

    MBRELL Precision Induction Heating 801-9526-00.doc This section details how to:  interpret the Status LEDs  understand system Faults and Advisories  program and execute continuous and multi-step heat-cycles (profiles) Interpret Status LEDs This guide will help you understand the operation of your E LED Status and system notices are relevant if your part is in the coil during HeatOn.
  • Page 30 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc  ● ●  AC Power; indicates E is ON; see the Status screen for notices Interpreting Faults, Limits and Advisories Your EASYHEAT communicates information about the way it’s operating. This section explains these conditions and what you can do () to respond to them. Fault Heating interrupted;...
  • Page 31 MBRELL Precision Induction Heating 801-9526-00.doc Multi-step profile Case: the part is brought to temperature and held in three steps (see chart on next page) From Control zone: Do this... Observe...  select ►Adjust Profiles Select Profile  then ►A  ...

  • Page 32: Equipment Maintenance

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc The graph represents the 3-step heating profile in the example Heating profile ‘A’ time (seconds)  Untimed profile steps are skipped (if they have non zero-setpoints)  Untimed and zero-Setpoint steps are interpreted as STOP by E (A4 implied, above).
  • Page 33 Ready, turn off water; ensure Fault; restore water. If no Fault, flow switch is stuck; do not operate further! Equipment safety is compromised. Call your Ambrell office 6 months coolant level; top-off if required appearance; flush & replace if dark or cloudy system;...

  • Page 34: Before You Call Service

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc … … If your heating results are inconsistent or have fallen below an earlier level, please refer to this section first to ensure that all electrical connections are secure.  ensure tap wiring and internal settings agree ...
  • Page 35 MBRELL Precision Induction Heating 801-9526-00.doc  remove cover from your workhead  examine all connections in both sides of boxed areas; ensure secure connections  examine your coil mounting connections; ensure secure connections Tighten all cap , buss connections Tighten all tap screws, inside, outside Clean, check, tighten all coil screws...

  • Page 36: Calibration

     return the power supply to us for us to perform this service; there will be a charge for this and a renewed Calibration Certificate will accompany the returned equipment. Contact Ambrell for details. The E work heads contain one or more water cooled capacitors, rated for current under laboratory (rather than real-world) conditions.
  • Page 37 MBRELL Precision Induction Heating 801-9526-00.doc How Your E Works...

  • Page 39: Customizing Your Easyheat

    MBRELL Precision Induction Heating 801-9526-00.doc You can control your E in different ways:  START / STOP can be controlled from the front panel or remotely  output level can be set from the front panel, remotely or with optional multi- step profiles you specify ...
  • Page 40 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Configuring Auxiliary Output Case: If your Quality Assurance requires external monitoring of System output, you can configure the System to provide scaled output (0—20 mA or 4—20 mA)** in Power, Amps, and Frequency modes. Auxiliary Output is provided on the rear connector panel (TB1) as “Aux Output”.
  • Page 41 MBRELL Precision Induction Heating 801-9526-00.doc 24V source & E-stop 24 V 24 V E-Stop E-Stop Case: (default) jumper ensures that Case: you include your E-stop switch; operation in not interrupted upon switch activation, RF heating is prevented or interrupted 24V source Signal Outputs 24V is an output from the EASYHEAT.
  • Page 42 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc If no E-stop device is used, EStop>Gnd terminals must be jumpered (factory configuration) for the E to operate. Flow switches (FLS) Internal flow switches protect your E from thermal damage if cooling water to the heat sink or to the coil is inadequate.
  • Page 43 MBRELL Precision Induction Heating 801-9526-00.doc START/STOP STOP START Case: use two external signals, switches or isolated contacts to control RF heating: START signal is normally-open, active-closed, STOP is normally-closed, active-open. 2-Button... Electrical Touch-pad ►System Options Attach your signal: Start From START N.O.
  • Page 44 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Remote Input Case: use an external signal to set the desired output level of the E . Depending on the signal source you plan to use (0-10Vdc is the default configuration), follow these instructions to change. Remote Remote Input...

  • Page 45: Serial Port (Rj45 Modular)

    The RS485 serial communication port is a standard feature of EASYHEAT. To enable serial communications, a converter kit is required. This kit with installation instructions is available (PN 305-0247). Contact Ambrell to order this kit. You can configure your own serial communication hardware and software to address EASYHEAT.
  • Page 46 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc To Configure the EASYHEAT If the converter kit (PN 305-0247) has been purchased and installed, follow these steps to prepare your E to make use of the serial communication option. Serial communication with E takes place when Home zone is displayed;...
  • Page 47 MBRELL Precision Induction Heating 801-9526-00.doc To Configure Your Computer The following is one way to configure the serial port of your computer; you may have your own devices or means of making the communications connection. Do this... Observe...  launch HyperTerminal from Programs > Accessories > Communication (or other serial communication application).
  • Page 48 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Using the Converter With the converter attached to your EKOHEAT and your PC as instructed above, Do this... Observe...  launch Hyper Terminal  Select File >> Open… dialog box listing ‘Connections’  Select your connection, Open ...
  • Page 49 MBRELL Precision Induction Heating 801-9526-00.doc Command set This table gives examples of each command’s use and the range of the data you can use in the command ‘argument’. The address is required and the commas between the address, command and arguments are required; do not insert spaces! Input is not case- sensitive.
  • Page 50 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Comm. Arg. Result Example Sets the amps setpoint to a percentage of amps output. % %amps must be enabled in the configuration menu to use this 1,%amps,45 command. Returns a list of commands and abbreviated descriptions of none each command.
  • Page 51 MBRELL Precision Induction Heating 801-9526-00.doc Sets the number of data lines between header lines. Example will place a descriptive header line every 25 replies when chdr 1,chdr,25 using the CDATA or CTEMP commands. The value range is 1 to 254. The default setting is 1 data line between headers. Continuous raw data while the heat is on.
  • Page 52 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Continuous 2 line response. Same as cdata without a line feed. Terminal window will not scroll. The rate at which the slcdata none 1,slcdata response is sent is based on the CTIME command. See ctime for description.

  • Page 53: Optional Equipment

    MBRELL Precision Induction Heating 801-9526-00.doc Pendant Styles At this writing, there are two models available:  3-lights, Start/Stop (upper) Input  2-lights, Start/Stop, Power Control (lower) Output 24 V E-Stop Fault HeatOn Ready The 3-light model puts Stop, Start and Status indicator in your hand.
  • Page 54 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Footswitch , enabling you to toggle HeatOn You can attach an optional footswitch to your remotely. In the first example, heating occurs only while you depress the switch; in the second, the footswitch starts a timed cycle Continuous Touch panel ►System Options...

  • Page 55: Eview Induction Heating Software

    MBRELL Precision Induction Heating 801-9526-00.doc eVIEW 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 parameters such as power, frequency, and tank voltage (or current) are displayed on a real time chart and saved in a spreadsheet.
  • Page 56  Capture external analog signals such as temperature. eVIEW is an accessory product offered for EASYHEAT and EKOHEAT power supplies. Contact Ambrell to learn more about eVIEW and see for yourself how PC based monitoring can improve your efficiency and productivity!

  • Page 57: Tap Adjustment

    MBRELL Precision Induction Heating 801-9526-00.doc Under certain heating conditions, E may ‘suggest’ or require changing your RF transformer tap settings (§2, Advisories...). For example: during HeatOn, an asterisk is shown on ►250A 234.00s the display. To read the message, 220A *190kHz ...
  • Page 58 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Follow these steps to change taps at the work head: Do this... Observe...  STOP unit is Ready  turn off AC power switch at rear AC power LED is not lighted  use Philips screwdriver to remove 3 work head cover screws (arrows) ...

  • Page 59: Re-Selecting Mains Voltage Range

    MBRELL Precision Induction Heating 801-9526-00.doc The equipment labelling indicates the mains voltage range for which your system has been configured. If you have a need to move the system into a facility with a different mains voltage range, follow these instructions: Electrical installations must be made by qualified personnel and must conform to applicable safety codes.
  • Page 60 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Do this... Observe...  STOP unit is Ready  turn off AC power switch at rear AC power LED is not lighted  ensure fused disconnect is open to remove all AC power from the system ...

  • Page 61: Storing The System

    MBRELL Precision Induction Heating 801-9526-00.doc 1. Turn System off. 2. Switch off mains and disconnect the System from the mains supply. 3. Using compressed air at P<1.5 bar(22psi), blow out all water circuits. This protects the water circuit and paths from corrosion, and from freezing in temperatures below 0 degrees Celsius.

  • Page 62: 5.1.1 Primary Regulation Techniques Not Used In Easyheat Products

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc 5.1.1 Primary regulation techniques not used in EASYHEAT products:  Adjustable DC power supply feed into the RF power stage - This method requires two power sections: one to adjust the DC level and the other to deliver RF. Examples of this can be found in the older Ameritherm Nova Star line, and in some competitor units.
  • Page 63 MBRELL Precision Induction Heating 801-9526-00.doc The load may be thought of as being in series with the coil. At any fixed tap, the EASYHEAT is presented with higher impedances corresponding to better coupling. Alternatively, an open coil or a very lightly loaded coil presents the EASYHEAT with a lower impedance. The lower the impedance, the more closely the application resembles a shorted coil with corresponding shorter run intervals.

  • Page 64: 5.1.2 Power Measurement

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc In practice, the recommended method of setting the workhead transformer tap is to begin with the highest tap available and see if the needs of the application can be met. This must be done with the actual load in the coil. If the desired setpoint current cannot be reached, the “Decrease tap”...
  • Page 65 MBRELL Precision Induction Heating 801-9526-00.doc Errors accumulate quickly:  Scope input gains must be turned down to accommodate higher crest factors, resulting in loss of scope resolution and accuracy.  The required use of two scope channels - with attendant differential phase and gain errors.

  • Page 66: Technical Information

    MBRELL ® Precision Induction Heating Doc#801-9526-00.doc Power Supply Feature Value Units Dimensions 437x687x183 (17x27x7) WxDxH mm (in) Internal access limited; cover secured with screws Mounting 19” rack or bench-top Weight 12.7 (28) kg (lb) Construction: aluminum Finish front panel black painted Your system uses and produces high voltages! Only trained or guided service persons are authorized inside the equipment.

  • Page 67: Electrical

    The equipment requires a connection to earth ground and does not make use of neutral. Failure to connect earth (safety) ground will result in a potentially hazardous condition. Do not omit this step! Equipment output Model 3542 4048 5060 7590 8310...

  • Page 68: Auxiliary Output Modes And Scaling Examples

    Doc#801-9526-00.doc Electrical installations must be made by qualified personnel and must conform to applicable safety codes. Do not connect 440V models to 230V mains; damage and hazard will result! Equipment input (440V models) Model 3542 4048 5060 7590 8310 units AC Line Power 11.2...
  • Page 69 MBRELL Precision Induction Heating 801-9526-00.doc Note: Full scale power is model-dependant. For example, model 8310 has a max power of 10kW. See “Equipment Input/Output” for complete listing of specifications for all models. 0—20mA Scale in “Power” mode: Model 8310 (10,000 Watts max rated) Where (Power in Watts)=(Aux_out_mA)*(max power in watts)/20 mA output Watts...
  • Page 70 MBRELL ® Precision Induction Heating Doc#801-9526-00.doc 4—20mA Scale in “Amps” mode Where Max Amps = Tap*25 (i.e., tap 22 would result in a full scale value of 22*25=550 amps.) (Current in Amps)=(Aux_Out_mA - 4)*(Max_Amps)/16 mA output Amps 68.75 343.75 All EASYHEAT LI’s have a frequency range scaled to 140-410kHz. 0—20mA Scale in “Frequency”...

  • Page 71: Environmental

    Range Units ambient temp 4 – 41 (40 – 105) C (F) water temp 20 – 35 (68 – 95) 3542 other models flow (system minimum) 3.8 (1.0) 5.7 (1.5 ) l/m (g/m) pressure 2.8 – 5.5 (40 – 80)

  • Page 72: Contact Information

    39 Main Street Scottsville, NY 14546 www.ambrell.com Tel: +1 585 889 9000 Fax: +1 585 889 4030 United Kingdom Ambrell Ltd. Phoenix Works, Saxon Way Cheltenham, Gloucestershire GL52 6RU salesuk@ambrell.com Tel: +44 (0)1242 514042 Fax: + 44 (0)1242 312011 France Ambrell Sarl Tour Sébastopol, 3 quai Kléber...
  • Page 73 MBRELL Precision Induction Heating 801-9526-00.doc Technical Information...

  • Page 75: Theory Of Coil Design

    remove this page and replace with 801-9038...

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