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

Use and maintenance manual
Page 46 of 137
8.4 KB Membrane series description
Key
1
Pump
2
Radiator
3
Antifreeze fluid tank
4
Main switch
5
Fuse holder
6
Power level adjustment buttons
7
Reset button
8
Power level signal LED
9
Handpiece error signal
10
Pump error signal
11
Antifreeze fluid temperature signal
12
Inductor
13
Heating start button
14
Inductor head
5
Fig. 1
Fig. 2

Use and maintenance manual
Page 47 of 137
8.5 Instructions for version with Key Board (KB) membrane keypad
•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 indicators (8, see Figure 3).
•Place the flow concentrator on the part to be heated (see Figure 5) and press the heating
start button (13, 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
8.5.1 Instructions of Autotuning with Keyboard (KB)
The exclusive Autotuning function developed by AIT is a special function that allows the same
machine to quickly self-configure the electronics, in the case of using special induction heads
outside the range of the standard ones.
Once the special head has been fitted, if the machine has the Keyboard proceed with Autotuning
as follows:
•Turn on machine and wait for self test
•Keep pressing “+” and press once “RESET”
•Leds start blinking → wait for Autotuning to end the process
•Leds stop blinking (if handle warning light goes on, Autotuning has been not successful)
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.

Use and maintenance manual
Page 48 of 137
8.6 Membrane keypad alarm lights
•LED 9 indicates a malfunction of the inductor head.
•LED 10 indicates a malfunction of the hydraulic circuit
•LED 11 indicates that the antifreeze liquid has reached the temperature threshold (ca.
45°C)

Use and maintenance manual
Page 49 of 137
9. Wiring diagrams
Model
Wiring diagram
HDI8K230KB
HDI11K400KB
HDI11K230KB
HDI13K400TC
HDI13K230TC
HDI16K400KB
HDI16K400TC
HDI18K400TC
HDI21K400TC
HDI23K400TC

Use and maintenance manual
Page 50 of 137
10. Hydraulic diagram

Use and maintenance manual
Page 51 of 137
11. Application of the warranty
11.1 Return of products to ALBATROS
If the reseller declares the malfunctioning of a product, they are required to submit the following
information to ALBATROS:
•product serial number
•a description of the problem with the product
•photo of encountered defects, if possible
The reseller can send defective products to ALBATROS, however they shall bear all shipment costs.
The company ALBATROS does not accept the return of products ex works.
Products shall be repaired and resent with a customer's successive order. In case of request for
sending in advance of order shipment, shipment costs shall be borne by the reseller.
If products are in warranty, spare parts and repair costs shall be borne by ALBATROS. If products
are not in warranty, ALBATROS shall issue a repair quote which the customer then accepts or
refuses. For all products in warranty returned for replacement or repair and which do not bear any
defect or malfunctioning, a debit document shall be issued for the check carried out on the product.
The warranty does not apply in the case of products resent without being appropriately packaged
and thus at risk of damage during shipment. Please take care as hauliers tend not to handle
packages with due care!!
11.2 Recommendations regarding product transport
The company ALBATROS only accepts carriage paid and not ex works returns.
The reseller is exclusively liable for damage caused to a product due to inadequate packaging, even
if the package is accepted by our warehouse. Since it is not possible to open each package upon
arrival, Albatros Trade Srl shall accept goods with reservation from haulier if there is visible damage
to packaging material.
11.3 Recommendations for packaging and transport
If possible, organise goods on pallets. This is considered the best solution to avoid damage to
products during shipment.
If required, that goods are packaged in cardboard using bubble wrap so that packaging absorbs
shock that may occur during shipment.
Place packaged product in very thick cardboard and ensure that all sides are wrapped in bubble
wrap or other material that can ensure protection of products as much as possible during shipment.

Use and maintenance manual
Page 52 of 137
11.4 Warranty duration and limits
A product remains in warranty for one year from date of purchase.
The warranty does not apply to the following cases:
- an external cause (mechanical shock, lightening, sudden changes in voltage)
- damage incurred during transport or storing
- a product installed in a manner that does not comply with manufacturer specifications
- a product containing too much dust in inner parts
- a product exposed to rain or humidity
- a product which has been modified by the client
- deteriorations caused by ill use of equipment
- use of unsuitable accessories or consumables
- natural wear of different parts of equipment
- freezing caused by insufficient or unsuitable use of the coolant
The guarantee does not apply to normal wear of accessories or consumables (ferrite).
If the equipment is modified or repaired by unauthorised personnel, the warranty shall be void.
CAUTION: The inductor (Fig. 4) must not be bent or altered in shape in any way. If the
inductor is modified, the warranty shall be automatically rendered void.
12. Replacing the inductor
Inductor replacement should be performed only by authorised personnel and only
after cutting off power to the machine.
Wear protective gloves during maintenance and/or repairs.
Electrically isolate the machine by disconnecting it from the mains.
When replacing the inductor, verify that there are no significant liquid leaks from the
manipulator. If there are any significant leaks, top up liquid in the corresponding tank.
Tightening should not exceed 5Nm when fastening the inductor. Tighten
using a suitable torque wrench.

Use and maintenance manual
Page 53 of 137
13. Maintenance
•Machine maintenance must be carried out by qualified, authorised personnel who are aware
of its operating procedures.
•Never perform any cleaning, lubrication or maintenance with the machine running.
•Before any maintenance work, set the main switch to "0" to cut off power, unplug it from the
mains to prevent electrical shock or other hazards resulting from mishandling.
•Never wear rings, watches, jewellery, loose or dangling clothing such as ties, torn garments,
scarves, unbuttoned jackets or jackets that zip open that can get tangled during work.
•It is instead advisable to use suitable clothes for accident prevention, for example: non-slip
shoes, anti-noise headphones, goggles, appropriate gloves, etc.
•Never use gasoline or flammable solvents to clean the machine. Use water and, if necessary,
commercial non-toxic solvents.
•After operations have been completed, always refit any protections that were removed before
re-starting the machine.
13.1 Preventive maintenance
Meticulous inspections carried out regularly are necessary in order to detect
and eliminate faults quickly before they can cause any major damage.
Any time you need to use the INDUCTOR HDi series, first check the
efficiency of safety devices, the conditions of connections and if there are any
anomalies by performing some no-load tests and on ferrous scrap material.
Check daily for wear and legibility of warning signs.
13.2 Routine maintenance
Machine operating safety can only be guaranteed if repairs are performed using only original or
however approved replacement parts and if maintenance instructions are followed correctly.
At the end of each use, with the machine disconnected from the electrical mains, proceed with a
general cleaning of the machine, quickly removing dust or dirt deposits in general as this could
reduce ventilation and alter machine function and durability.
Before each use, verify the functionality of control devices, safety devices and the conditions of
electrical connecting cables.

Use and maintenance manual
Page 54 of 137
13.2.1 Cooling liquid replacement and Hydraulic system purge
After a working period of about 1 year, due to coolant properties degradation, it is recommended to
replace the antifreeze cooling liquid to increase the service life of the machine components and for
a more efficient duty cycle.
Proceed as follows to replace the antifreeze fluid:
1. Turn off the machine
2. Remove the front panel of the machine to access the fluid tank
3. Close the hydraulic tap valve at the tank bottom
4. Place absorbent cloth to dry any liquid that can escape from a small section of the circuit
5. Release the rilsan hose from the tank bottom
6. Release the rilsan hose from the pump outlet (top) by pressing the ring
7. Use compressed air pressure attached to the “rilsan hose pipe” to clean the system it
completely
8. Re-insert the rilsan hose into the pump outlet (top)
9. Unscrew the hose clamp nut over the tank cap
10. Remove the tank closing cap (together with the meshed rubber hose)
11. Take the tank off and empty completely the tank
12. Reposition the tank and reconnect the rilsan hose at the tank bottom
13. Open the hydraulic tap valve at the tank bottom
14. Fill approx. 20 L of new antifreeze liquid.
15. Close the tank with the cap, start the machine and wait a few seconds for the circuit
supplying the inductor to charge.
13.2.2 Replacing the flow concentrator
In the event of flow concentrator (ferrite, Figure 7) replacement
Figure 7
Remove the screws fastening the brass tab, extract the flow concentrator, carefully clean the copper
part and replace the worn concentrator with a new one fastening it with the appropriate tab and the
respective screws
Figure 8

Use and maintenance manual
Page 55 of 137
13.2.3 Unlocking the pump
If, when the machine is started, the user panel (figure 3) signals the error on the hydraulic circuit,
open the front panel of the machine, check that the antifreeze fluid is flowing; otherwise, after
switching off the machine, insert a screwdriver into the hole provided, move the pump fan until it is
unlocked, see Figure 9:
Figure 9
Note: Contact the manufacturer or an authorised dealer whenever there are any breakages requiring
the removal of machine.
14 Accessories & Special optional versions
14.1 Accessories
14.1.1 Heat sensor iRT (ONLY for TC Version )
The iRT heat sensor is ideal for targeted heating. It is equipped with integrated laser electronics in
the head that detects temperatures from -30°C to 1000°C on metals, oxides and ceramics. Its laser
cross-pointing system offers reliable and precise adjustment of the measuring range even when
conditions are difficult, for example when there is heat transfer.