AIT HDi 8K230 KB User manual

Manuale uso e manutenzione
Use and maintenance
manual
HDi 8K230 KB
HDi 18K400 TC
HDi 11K400/230 KB
HDi 21K400 TC
HDi 13K400/230 TC
HDi 23K400 TC
HDi 16K400 KB/TC

General contents
1. Safety instructions ..............................................................................................................................................................................38
2. Connection.........................................................................................................................................................................................40
3. Maintenance..................................................................................................................................................................................40
4. Regulatory information...................................................................................................................................................................40
5. Disposal ........................................................................................................................................................................................40
6. Product identification .....................................................................................................................................................................40
7. Product specifications....................................................................................................................................................................41
8. Description of devices....................................................................................................................................................................42
8.1 TC series description.....................................................................................................................................................................43
8.2 Instructions for use of version with Touch control (TC)...................................................................................................................44
8.2.1 Instruction of Autotuning with Touch Control (TC) ....................................................................................................................44
8.3 TC alarm lights ..............................................................................................................................................................................45
8.4 KB Membrane series description .................................................................................................................................................46
8.5 Instructions for version with Key Board (KB) membrane keypad....................................................................................................47
8.5.1 Instructions of Autotuning with Keyboard (KB).........................................................................................................................47
8.6 Membrane keypad alarm lights......................................................................................................................................................48
9. Wiring diagrams .................................................................................................................................................................................49
10. Hydraulic diagram.............................................................................................................................................................................50
11. Application of the warranty................................................................................................................................................................51
11.1 Return of products to ALBATROS ................................................................................................................................................51
11.2 Recommendations regarding product transport ...........................................................................................................................51
11.3 Recommendations for packaging and transport ...........................................................................................................................51
11.4 Warranty duration and limits ........................................................................................................................................................52
12. Replacing the inductor......................................................................................................................................................................52
13. Maintenance.....................................................................................................................................................................................53
13.1 Preventive maintenance ..............................................................................................................................................................53
13.2 Routine maintenance...................................................................................................................................................................53
13.2.1 Cooling liquid replacement and Hydraulic system purge........................................................................................................54
13.2.2 Replacing the flow concentrator.............................................................................................................................................54
13.2.3 Unlocking the pump...............................................................................................................................................................55
14 Accessories & Special optional versions.........................................................................................................................................55
14.1 Accessories.................................................................................................................................................................................55
14.1.1 Heat sensor iRT (ONLY for TC Version )................................................................................................................................55
14.1.2 Alternative standard flow concentrators .................................................................................................................................56
14.1.3 Special flow concentrators.....................................................................................................................................................57
14.2 Special optional versions.............................................................................................................................................................59
14.2.1 Induction machines with Smart heating switch.......................................................................................................................59
14.2.2 Induction machines with Foot pedal switch............................................................................................................................59
14.2.3 Induction machines with timer................................................................................................................................................59
15. Exploded views ................................................................................................................................................................................60
15.1. HDI 11K230 KB ..........................................................................................................................................................................60
15.2. Exploded view HDI 11K400 KB...................................................................................................................................................61
15.3. Exploded view HDI 13K230 KB ..................................................................................................................................................62
15.4. Exploded view HDI 13K400 KB ..................................................................................................................................................63
15.5. Exploded view HDI 13K400 TC ..................................................................................................................................................64
15.6. Exploded view HDI 16K400 /18K400 KB ....................................................................................................................................65
15.7. Exploded view HDI 16K400 /18K400 TC ....................................................................................................................................66
15.8. Exploded view HDI 21K400 /23K400 TC ....................................................................................................................................67
16. Machine logbook ..............................................................................................................................................................................68
17. Conformity........................................................................................................................................................................................69

Use and maintenance manual
Page 38 of 137
1. Safety instructions
This manual describes the operation of the unit and the precautions to be taken for
your safety.
Read it carefully before use and keep it in a safe place for future reference.
These instructions must be read and understood before use.
Do not undertake any modifications or maintenance other than those specified in the
manual. The manufacturer shall not be held liable for physical or material damage
due to improper use of the equipment
In case of problem or doubt, please consult a qualified person to use the unit
correctly. The safety instructions must be observed.
The manufacturer declines all liability in the event of improper or hazardous use. Any
use not mentioned in this manual is strictly forbidden and potentially dangerous.
This machine should only be used for the purpose for which it was expressly
designed, that is: to generate heat inside ferrous materials.
Any other use not expressly covered in this manual is strictly prohibited as considered
improper and therefore dangerous. The machine is semi-automatic and therefore
requires the presence of an operator.
The operator has the direct responsibility for compliance with all safety standards not
only where he is concerned but also for any persons who may be exposed to machine
risks.
Do not use the unit if the power cord or plug is damaged.
Caution! Very hot surface. Risk of burns.
•Overheated objects and equipment can cause burns.
•Do not touch hot objects with bare hands.
•Wait for the objects and equipment to cool down before using them.
In case of burns, rinse with plenty of water and seek medical advice immediately.
•Machine use should only be entrusted to adult, suitably trained personnel in
full compliance with current regulations and the instructions contained in the
manual.
•Remove any jewellery and/or metal object before using this unit.
•Keep the machine in a suitable place, protected from weathering.
Danger from gases and vapours.
•Keep away from fumes and do not breathe vapours.
•When working indoors, ventilate the room and/or use an air extractor to
evacuate vapours and gases.
•Induction heating of certain materials, adhesives and fluids can produce
vapours and gases. Breathing these gases and vapours may be dangerous
to your health.
•If ventilation is insufficient, use a certified respirator.
•Read the product technical and safety data sheets (MSDS) and the
manufacturer's instructions for adhesives, metals, coatings, detergents, and
pickling agents.
•Do not use the heater on degreasing or spraying parts. Heat can react with
vapours to form highly toxic and irritating gases.

Use and maintenance manual
Page 39 of 137
•Only work in a confined space if it is well ventilated or using a certified
vacuum cleaner. Vapours and gases resulting from heating can replace the
oxygen in the air and cause sickness or death. Verify the quality of the air
you breathe.
•Do not overheat metals, such as galvanized steel, lead-coated steel, or
cadmium-coated steel, unless the coating is removed from the surface to be
heated, air is well ventilated, and, if necessary, wear a certified respirator.
Castings and all metals containing these elements can release toxic
vapours when heated.
•Refer to the MSDS for temperature information
Caution! Electrical hazard.
Caution! Strong magnetic field. Persons having active or passive implants
must be informed.
Do not approach the inductor at the head and vital parts level during operation.
Persons with pacemakers or biomechanical equipment should not use the device.
Risk of disturbances/interference in the operation of pacemakers/ biomechanical
equipment in the vicinity of the device.
Wear PPE during use

Use and maintenance manual
Page 40 of 137
2. Connection
This unit must be connected to a properly grounded electrical outlet.
3. Maintenance
•Maintenance must be carried out by qualified personnel.
•Warning! Disconnect the machine cable from the power supply before
performing any maintenance on the unit.
•Never use solvents or other aggressive cleaning products.
•Clean the surfaces of the unit with a dry cloth.
4. Regulatory information
Device in compliance with European directives
Device in compliance with UK directives
EAC (Eurasian Economic Community) mark of conformity
5. Disposal
This material is subject to separate waste collection. It must not be disposed of
with household waste.
6. Product identification
A label is located on the back of the machine:
•Name and address of manufacturer
•Date of manufacturing
•Model
•Type of product
•Operating voltage

Use and maintenance manual
Page 41 of 137
7. Product specifications
HDI
8K230 KB
HDI
11K400 KB
HDI
11K230 KB
HDI
13K400 TC
HDI
13K230 TC
HDI
16K400 TC
HDI
16K400 KB
HDI
18K400 TC
HDI
21K400 TC
HDI
23K400 TC
Rated power
8 Kw
11 Kw
11 Kw
13 Kw
13 Kw
16 Kw
16 Kw
18 Kw
21 Kw
23 Kw
Rated voltage
230 V
400 V
230 V
400 V
230 V
400 V
400 V
400 V
400 V
400 V
Power supply voltage
frequency
50-60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50– 60 Hz
50-60 Hz
Plug amperage
16 A
16 A
32 A
32 A
32 A
32 A
32 A
32 A
32 A
63 A
Heater frequency
15-30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15–30 KHz
15-30 KHz
Insulation class
IP 21
IP 21
IP 21
IP 21
IP 21
IP 21
IP 21
IP 21
IP 21
IP 21
Coolant tank capacity
20 L
20 L
20 L
20 L
20 L
20 L
20 L
20 L
20 L
20 L
Power supply cable
length
8 m
8 m
8 m
8 m
8 m
8 m
8 m
8 m
8 m
8 m
Inductor cable length
3 m
4.25 m
4.25 m
4.25 m
4.25 m
4.25 m
4.25 m
4.25 m
4.25 m
4.25 m

Use and maintenance manual
Page 42 of 137
8. Description of devices
Model
Description
Details
TC
See par. 8.1
KB
See par. 8.4

Use and maintenance manual
Page 43 of 137
8.1 TC series description
Key
1
Pump
2
Radiator
3
Antifreeze fluid tank
4
Main switch
5
Fuse holder
6
Power level adjustment buttons
7
Power level signal bar
8
Power output display
9
Antifreeze fluid temperature display
10
Electronic temperature display
11
Transformer temperature display
12
Laser sensor temperature setting button
13
Timer button
14
Diagnostic ad WiFi button
15
Inductor
16
Heating start button
17
Inductor head
5
6
7
15
16
17
12
13
14
Fig. 4
Fig. 3
8
9
10
11

Use and maintenance manual
Page 44 of 137
8.2 Instructions for use of version with Touch control (TC)
•Turn the main switch (4, Figure 1) to ON position. The machine checks the system and
prepares to work, then wait a few seconds.
•Use the buttons (6, Figure 3) to select the desired power level. These levels are shown by
the power level indicator (7, see Figure 3).
•Place the flow concentrator on the part to be heated (see Figure 5) and press the heating
start button (16, Figure 4).
•In case of use of any alternative flow concentrator different from the serial version the
machine can operate by using the adaptive inductance field reading (autotuning)
Correct
NOT Correct
Figure 5
8.2.1 Instruction of Autotuning with Touch Control (TC)
When using special induction heads outside the standard range, AIT's unique auto-tuning feature
allows the machine itself to quickly auto-configure the electronics to the specific inductor head
inductance to maintain maximum efficiency.
If if the machine has the Touch control proceed with Autotuning as follows:
•Press the Diag/WiFi button
•Press the Diag button
•Scroll the right arrow to TEST 03
•Press the PLAY icon and wait for the end of the test.
•Press the Back button to return to the main page
To reset the original configuration with the standard inductor head:
•Select TEST 04
•Press the PLAY icon and wait for the end of the test.
•Press the Back button to return to the main page.

Use and maintenance manual
Page 45 of 137
NOTE: If the machine is used for long periods of time, it is advisable to leave it switched on for a few
minutes before switching it off, so that the liquid in the tank can cool down more quickly.
The machine has been designed to minimize the risks due to electromagnetic
fields. Additional risks exist and it is recommended to keep a minimum safety
distance of 30 cm between the inductor and the operator's head or bust.
8.3 TC alarm lights
The display will show the error code in case of fault detection. Please contact customer service with
the code shown on the display.
Touch Control Display (TC) specific
manual