Ambrell EasyHeat 0112 Release Note

Technical Handbook
Induction Heating Systems for 1.2kW – 2.4kW
Models 0112, 0224
File Name 801-9309.doc
Part Number 801-9309
Revision Rev F
ECN# 1606-08
By Mike Bond
Approved Dan King
Date 06/28/2016

Revisions:
Rev D was written to:
•Update RS485 command set
Rev E (ECN1308-06) was written to:
•Update back panel figures
•Correct Serial Port enabling via converter kit information
Rev F (ECN1606-08) was written to:
•Correct the “Electrical Equipment Input” table
Ambrell Corporation
United States
[phone]
Ambrell, Ltd.
United Kingdom
[phone]
801-9309.doc RevF © 2013 All information subject to change without notice
Ambrell B.V.
The Netherlands
[phone]
Ambrell SARL
France
[phone]

3
801-9309.doc
Table of Contents
1Introduction .....................................................................................................................5
1.1 Safety Considerations ..................................................................................................6
1.2 Front Panel ..................................................................................................................7
1.3 Rear Panel ...................................................................................................................8
1.4 Assembly.....................................................................................................................9
2How Your EASYHEAT Works.....................................................................................13
2.1 Home Zone................................................................................................................14
2.2 Control Zone .............................................................................................................20
2.3 Detailed EASYHEAT Operation ...............................................................................25
2.4 Equipment Maintenance ............................................................................................29
2.5 Calibration.................................................................................................................30
2.6 Smartburst Technology..............................................................................................31
3Customizing Your EASYHEAT....................................................................................33
3.1 Rear Panel Connections .............................................................................................33
3.2 Optional Pendant .......................................................................................................38
3.3 Serial Control (optional) ..............................................Error! Bookmark not defined.
3.4 eVIEW Induction Heating Software...........................................................................48
3.5 Tap Adjustment (IHS only)........................................................................................49
3.6 Cap Replacement (IHS only) .....................................................................................51
3.7 Tap Adjustment; 1-Cap RHS .....................................................................................52
3.8 Tap Adjustment; 2-Cap RHS .....................................................................................53
3.9 Cap Replacement; 1-Cap RHS ...................................................................................55
3.10 Cap Replacement; 2-Cap RHS ...................................................................................56
4Technical Information ...................................................................................................57
4.1 Mechanical ................................................................................................................57
4.2 Electrical ...................................................................................................................57
4.3 Environmental ...........................................................................................................58
5Theory of Coil Design ....................................................................................................59

4
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
EASYHEAT (RHS) Free Front with remote heat station
EASYHEAT (IHS) with internal heat station
EASYHEAT (RHS) with remote heat station

Introduction 5
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1
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 single-phase
line voltage to a 1.2kW or 2.4kW terminal output over a range of radio frequencies (RF)
and voltages. This energy is delivered to a series-resonant circuit - including your coil -
where a precisely controlled magnetic field is created around your work-piece.
EASYHEAT uses a special sensing technology enabling greater control of your process;
precise frequency registration under varying load conditions results in increased precision
in heat control and times-to-temp.
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
•electrically isolated remote water-cooled heat station
•routine internal access not required, no DIP switches used
•Free-Front configuration co-locates all utilities at the rear
The power from your supply can be controlled:
•manually from the front panel
•remotely by your signals provided to the rear panel
•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 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:
•EASYHEAT power supply
•line cord
•remote heat station with cable (RHS models)
•reference coil, complete with locking compression fittings
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.

Introduction
6
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:
Safety Circuits
Your optional normally-closed E-stop switch can be installed in series with the system
24Vdc supply (CTB1:15-16); when the switch opens, all output power and operations
cease. 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 3A
@24Vdc.
The power supply is fitted with an external rear panel jumper (CTB1:15-16) which must
be removed to insert any safety switches required.
•
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.

Introduction 7
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1. .2 2 F Fr ro on nt t P Pa an ne el l
(RHS) Hoses & RF Cables
The remote heat station attaches here. A circular plastic connector conveys
RF energy to the cable and heat station; plastic tubing routes cooling water
to and from the heat station. Free-Front configuration (right) co-locates all
utilities at the rear of your power supply.
IHS Models
The coil used to apply RF energy to your part attaches here. Compression fittings for ¼”
tubing are provided. A coil kit is supplied with some orders.
Touch-pad & Display
•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
Hoses and RF Cable
Handles Status
Navigation
START/STOP
Display AC indicator
Handles
Coil and terminal
s
Status
Navigation
START/STOP
Display
AC indicator

Introduction
8
1
1. .3 3 R Re ea ar r P Pa an ne el l
Water connections (A)
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
are used to interrupt heating operations if this flow is inadequate. Temperature sensors
are used to reduce heating if the internal temperature rises too high
Terminal block (CTB1) (B)
Electrical connections are made here for all input and output signals (§3).
Heat sink (C)
A heat sink is used with your cooling water to extract heat from internal components.
Power switch, circuit breaker (D)
This rocker-switch completes the line connection to the power supply. It includes a 15A
circuit breaker and an EMI line filter. IEC 60320 receptacle accepts a modular line cord
assembly (included).
Line cord entry (D)
The included 8’ line cord attaches here. As an additional safety measure, you must
disconnect the line cord here in order to remove the cover to service the unit.
RJ45 connection (E)
To facilitate serial communications.
RF cable connection (F)
RF cable from the remote heat station (RHS) plugs into this receptacle.

Introduction 9
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1. .4 4 A As ss se em mb bl ly y
Take these factors into consideration as you determine where to install your system:
•availability of water and drain
•availability of AC power outlet
Attach heat station (if not attached)
unscrew protective cap
insert indexed heat station plug
tighten ring nut
insert RED tubing fully into bottom port
insert clear tubing fully into top port
…to remove tubing
use small slotted driver; pry off collets
push in on retaining rings, pull out tubes
replace collets
Work-coil or reference coil (included with the unit)
Reference coil is included to assure basic operation; suitable for use in heating
remove two nut/ferrule assemblies from heat station terminals; retain for future use
locate work-coil; apply nuts and ferrules;
insert coil at the heat station connections;
assure that coil is fully seated in the fittings
assure that coil is aligned to your needs
(vertical, horizontal, etc.)
use 5/8” wrench to hold the bulkhead nut
use 9/16” wrench to tighten (clockwise) two
compression nuts to the unit
Work-coil (your construction)
wind your coil allowing 2” equal-length leads
(min) for connection to the equipment
trim and de-bur each lead
to each lead, apply one (diagram)
nut
rear ferrule
front ferrule
fully insert both leads into the equipment bulkhead
use 5/8” wrench to hold the bulkhead nut
use 9/16” wrench to tighten each coil nut
Swagelokspares: Nut B-402-1; front ferule B-403-1;
rear ferrule B-404-1
1
2
3
4
5
1/4" tube
your coil
nut
rear ferrule
front ferrule
for Free-Front models: same procedure - at rear

Introduction
10
Rack/panel Mounting
Your EASYHEAT is mountable in your panel or 19” rack (3U); observe these steps and
requirements:
unscrew/remove 4 rubber feet on unit base
(panel) provide cutout and mounting pattern per above; plan for M5 or M6 screws
ensure that rear of unit is supported when mounted
provide at least 17” depth to permit water and AC cordage bend
secure unit with M5 or M6 hardware
Cooling water
In the process of heating your work-piece, the current flowing in the heat station and
power supply heats components, too. It is necessary to dispose of this excess heat to
prevent damage to the components.
EASYHEAT 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 drain or to cooling
to be recycled back to the equipment.
Follow these important restrictions:
•If used, fill re-circulating system with distilled water
•Do not use de-ionizing water systems
•Do not use inhibited glycols as anti-rust or anti-freeze agents
•(If cooler is not supplied by us) Install a pressure regulator and a particulate
matter filter (both non-ferrous) in the supply of your cooling water.
•Do not use ferrous pipe for this system; it can lead to equipment damage!
Establish a cooling water source capable of 40psi differential pressure across the
system and at least 0.7 g/m (2.6 l/m) flow
Provide inlet and outlet water through ¼” copper or plastic tubing
Cut each tube end cleanly and remove any burrs
Insert supply tube end fully into fixture labeled INLET
1.5 (38)
18.3 (465)
2.25 (57)
17.5 (445)
5.2 (132)
Not to scale; inch (mm)panel cutout