Ambrell 3542 User manual

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

Revisions:
Rev J: Add Auxiliary Output feature content
Rev K: Correct specifications (physical and electrical)
Rev L: Correct RS485 communication kit information. Correct bend
radius measurement specification.
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
www.ambrell.com
+1.585.889.9000
Ambrell Ltd.
www.ambrell.com
[phone]
801-9526-00.doc Rev P | © 2015 All information subject to change without notice
Ambrell Sàrl
fr.ambrell.com
[phone]
Ambrell B.V.
nl.ambrell.com
[phone]

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Table of Contents
1Introduction ..........................................................................................................................5
1.1Safety Considerations........................................................................................................6
1.2Front and Rear Panels .......................................................................................................8
1.3Work Head ......................................................................................................................10
1.4Assembly.........................................................................................................................11
1.5Installation.......................................................................................................................14
2How Your EASYHEAT Works ........................................................................................17
2.1Home Zone......................................................................................................................18
2.2Control Zone ...................................................................................................................24
2.3Detailed EASYHEAT Operation ....................................................................................29
2.4Equipment Maintenance..................................................................................................32
2.5Before You Call Service… .............................................................................................34
2.6Calibration.......................................................................................................................36
2.7Smartburst Technology ...................................................................................................36
3Customizing Your EASYHEAT .......................................................................................39
3.1Rear Panel Connections ..................................................................................................39
3.2Serial Port (RJ45 modular)..............................................................................................45
3.3Optional Equipment ........................................................................................................53
3.4eVIEW Induction Heating Software ...............................................................................55
3.5Tap Adjustment ...............................................................................................................57
3.6Re-selecting Mains Voltage Range .................................................................................59
4Storing the System..............................................................................................................61
4.1System Disposal ..............................................................................................................61
4.2Sorting .............................................................................................................................61
5Regulation, Efficiency and Power Measurement ............................................................61
5.1RF Regulation and Efficiency .........................................................................................61
5.1.1Primary regulation techniques not used in EASYHEAT products:.........................62
5.1.2Power Measurement.................................................................................................64
6Technical Information .......................................................................................................66
6.1Mechanical ......................................................................................................................66
6.2Electrical..........................................................................................................................67
6.3Auxiliary Output Modes and Scaling Examples.............................................................69
6.4Environmental .................................................................................................................71
6.5Contact Information ........................................................................................................72
7Theory of Coil Design ........................................................................................................75

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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

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1 I In nt tr ro od du uc ct ti io on n
Your EASYHEAT is a solid-state induction heating system that converts three-phase line
voltage to 4.2, 6, 9 or 10kW terminal power output (depending on model) over a range of
radio frequencies (RF) and voltages. This energy is delivered to a remote series-resonant
circuit - including your coil - where a precisely controlled magnetic field is created
around your work-piece. Available power to your process depends on the coupling
efficiency of your coil due to its geometry and proximity. Efficiency also depends on the
properties of your part; induction heating generally couples more efficiently to magnetic
steel and graphite parts than it does to non-magnetic stainless steel, aluminum and
copper.
Special features
Your EASYHEAT simplifies and improves your heating results with:
Touch-pad interface for control and programming
Backlit LCD simultaneous display of up to four data fields
Analog output – user programmable to represent Coil current, RF power or
operating frequency
electrically isolated remote work head
The power from your supply can be controlled:
manually from the front panel
remotely by your signals provided to the rear panel
remotely through a configurable serial port
from one of four 5-step profiles you specify
This selection is made from the touch-pad and can be changed at any time.
Unpacking
Your Ambrell EASYHEAT 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. Look for dents, crushed
corners or torn cartons.
YOU MUST REPORT ALL DAMAGE DIRECTLY TO THE CARRIER.
Check to see that all the parts we shipped arrived at your plant with your manual:
EASYHEAT power supply
remote work head with cable
reference coil, attached to mounting blocks
this manual

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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.
1
1. .1 1 S Sa af fe et ty y C Co on ns si id de er ra at ti io on ns s
Your EASYHEAT uses RF energy to raise the temperature of your work-piece. Most of
this RF energy is transmitted into the work-piece and some is transmitted into the air.
Physical Risks
During the HeatOn cycle, high RF voltages are present at your work-coil. There are
several risks, which we instruct you to protect against:
Electrical installations must be made by a qualified electrician and must conform to
applicable safety codes.
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!
High Temperatures: take steps to prevent personal contact with the work-piece you are
heating. Severe burns can result from contact at these temperatures! The mounting frame
on the bottom can heat during normal use, mount work-head to non-flammable surface,
and do not touch until cooled.
RF Voltages: we recommend that you provide protection against personal contact with
the work-coil when it is energized (Heat On).
Induction burns: the energized work-coil causes nearby metals to become heated; DO
NOT APPROACH ENERGIZED WORK-COIL WHILE WEARING OR CARRYING
METAL OBJECTS!
Electric and magnetic fields (EMF): EMF can affect Implanted Medical Devices.
Implanted Medical Device wearers should consult their doctor and the device
manufacturer before going near induction heating operations.

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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.
The power supply is fitted with an external rear panel jumper which must be removed to
insert any safety switches required.
Class A equipment is intended for use in industrial environments. There may be
difficulties in ensuring electromagnetic compatibility in other environments due to
conducted and/or radiated disturbances.
Group 2 equipment intentionally generates radio frequency fields for the treatment
of materials

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1. .2 2 F Fr ro on nt t a an nd d R Re ea ar r P Pa an ne el ls s
Touch-pad & Display
All user-interface is conducted here
Status LEDs indicate what your EASYHEAT is doing
AC indicator is lighted when unit is turned on
LCD display provides operating information, navigation/programming prompts
START/STOP buttons enable front panel control of heating
navigation buttons are used to program and control the unit
Handles StatusDisplay AC indicator
START/STOP Navigation

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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.
Your EASYHEAT uses circulating water to cool internal components and the coil; inlet
and outlet connections for the entire system are made at the rear. Internal flow switches
and temperature sensors are used to interrupt heating operations if this flow is inadequate
and are used to reduce heating if the internal temperature rises too high. Cooling water is
directed to and from the work head through the chassis and monitored by the power
supply.
Circuit breaker
This gang-switch controls the mains connection to the power supply. Trip level may vary
by model; see §4.
AC Line Inlet
This strain-relief fitting secures the provided 4-wire AC mains cabling.
Terminals (TB1)
Electrical connections are made here for all input and output signals (§3).
Grounding Studs
Safety Stud: Ensure that this auxiliary protective earth is connected to your facility
safety grounding before applying AC power.
Signal Stud: For signal grounding connections; not for equipment safety ground
connection!
TerminalsRF Output, terminals (cover removed)
Work Head WaterSystem Water
Circuit Breaker AC Line Inlet
Signal Stud Safety Stud

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1. .3 3 W Wo or rk k H He ea ad d
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.
Water is directed through the work head to draw-out excess heat developed naturally in
the internal components.
In cases where your coil presents a very restrictive path for the cooling water, we may
recommend the use of a ‘bypass-block’, §3. This may also require the use of an external
flow switch. (Ask your sales representative) Wiring must then be brought back to the
power supply from this switch.