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
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
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

Introduction 11
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Insert drain tube end fully into fixture labeled OUTLET
(To remove tubing, press retaining ring while pulling on tube.)
Flow monitoring
The amount of water flowing through your equipment is monitored, since inadequate or
absent cooling water can result in damage to the coil or capacitor. When flow is adequate
to the heat sink and to the coil – 0.7 g/m (2.6 l/m) or more total – two internal switches
are closed. When flow falls off to the heat sink or the coil, one or both of the switches
open and the power supply senses it, halts RF power and indicates ΩFault.
No action required by you; internal connections.
Line cord
Your EASYHEAT power supply accepts line-voltage through this cord. The power
switch module includes a circuit breaker rated for your equipment.
assure unit cover is attached and secure; assure power switch is OFF
insert line cord at rear of unit
insert line cord into grounded outlet
turn power switch ON
Start-up display
Upon power-up, certain important information about your EASYHEAT is displayed:
Output power capability: Depending on the unit
you purchased, 1kW RF Power or 2kW RF
Power
Firmware versions: There may be instances where
we need this information from you. n.nn
represents the version numbers of the Display or
Main firmware
SYS ID #: The SYS ID# is used to connect to
remote monitoring software. Refer to § 3.4 for
more information on eView Induction Heating
Software.
You can also view the output power capability screen and the Firmware version screen
when the unit is ON; while in the Control Zone, §2.2, press ▲or ▼to repeat the
Start-up display screens
The next section explains what you see when the unit is operating in the Home zone.
EASYHeat 1012
1kW RF Power
Display: Vn.nn
Main: Vn.nn
Certain cooling configurations can significantly restrict flow, limiting
EASYHEAT’s efficiency. Under these conditions, you must supply water to the unit
from 3/8” tube and adapt to ¼” at the unit if:
•supply line lengths exceed 5 feet
•EASYHEAT is in series with another power supply or component
SYS D # = nnnnn

Introduction
12

How Your EASYHEAT Works 13
801-9309.doc
2
2 H Ho ow w Y Yo ou ur r E EA AS SY YH HE EA AT T W Wo or rk ks s
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.
With HeatOn, both Setpoint (your selected output level) and Output Level (actual
power or current delivered to your part) are displayed. Typically, the Output Level is
highest when your part is in the coil and it returns to a lower level when you remove your
part. (For detailed explanations or to understand operation that is not typical, see §2.3)
This equipment is designed to operate simply. This section presents EASYHEAT operation
in two parts:
•Home zone: your EASYHEAT operates in this zone when you first apply
power. The factory settings enable you to get right to work heating parts by
operating the front panel. From the Home zone, you can adjust output levels,
set the timer and turn RF power on and off. Simple heating jobs may never
require you to use features outside this zone.
•Control zone: press this button to make use of the full set of EASYHEAT
capabilities by changing any of the operating characteristics. Refer to §2.2 to
customize your EASYHEAT.
•Return: pressing this button always returns display to the Home zone
Next is a simple example of operation from the Home zone. In it you will operate your
EASYHEAT by:
•starting from the front panel
•using 2-button START (requires STOP to turn off heat)
(Other operating characteristics are discussed in the Control zone section.)
After this example, the front panel display, LED and touch-pad features are explained.
The Control zone is explained in detail in the next section.
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

How Your EASYHEAT Works
14
2
2. .1 1 H Ho om me e Z Zo on ne e
When you turn it on, EASYHEAT operates in the Home zone (illustration). Within this
zone, you can adjust output levels, set the timer and turn RF power on and off:
Simplest example…
In this example, you heat the part at 100A output.
►
0.0A Untimed
0.0A 0kHz
►100.1A Untimed
0.0A 0kHz
►100.1A Untimed
100.1A 100kHz
1
3
○
Ready HeatOn Fault
○○
Ready HeatOn Fault
2
○○
Ready HeatOn Fault
2
Status LEDs
indicate what your EASYHEAT is doing:
READY: waiting to heat; no faults detected
HEAT ON: power is being output
FAULT: heating interrupted, fault detected
AC Power
indicates your
EASYHEAT is
turned on
Navigation
to program and
configure
START/STOP
to initiate heating from front panel
Timer
cycle or continuous
Setpoint
required output level
Output level
(A, W, % or units)
Output frequency

How Your EASYHEAT Works 15
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Do this... Observe...
open water-valve for the system check drain; assure water is flowing
check the work-coil assure there is no work-piece yet
check condition of (any) safety
barriers or limit switches
all safety devices are clear, electrically
closed
turn on EASYHEAT AC Power and Ready LEDs (are ON)
note display: assure Setpoint is selected (example)
press ▲, adjust until: 100A
Within the
Home
zone, use these buttons to adjust Setpoint and Timer
(indicated with the display pointer ►); press once to make a single-step
adjustment, or you can hold the button to scroll quickly to a new value.
press ▲, adjust until: 10.00s
10.00s10.00s
10.00s
secure unheated part in coil part not contacting coil; do not hold
press START HeatOn, Ready
Ready only, when timer expires (HeatOff
remove heated part from coil avoid contact with heated portions
secure unheated part in coil part not contacting coil; do not hold
press START HeatOn, Ready
press
STOP
Ready
only
Press
START
to begin induction heating (
Home
zone only)
Press STOP to halt induction heating (2-button start type, below). STOP
signal from front or rear panel always halts induction heating.
remove heated part from coil avoid contact with heated portions
Timed heating…
In this example, you heat the part at 100A output for 10 seconds.
Do this... Observe...
press ►, select Timer Untimed
UntimedUntimed
Untimed
Button is used to move the display pointer from one data field to the next.

How Your EASYHEAT Works
16
Display features
At the top left corner of the screen, this is your desired output level, displayed in RF
amps. Larger values result in faster heating or hotter parts. With the pointer (►) on
Setpoint
SetpointSetpoint
Setpoint, you can increase or decrease the setting with the ▲/▼buttons.
EASYHEAT works to match the RF output to this setting when the RF power is on
(HeatOn). In the Home Zone, ►moves the cursor between Setpoint
SetpointSetpoint
Setpoint and Timer
TimerTimer
Timer.
At top right, use the timer to control the duration of your heating. With the pointer (►)
on Timer
TimerTimer
Timer, you can increase or decrease this setting to values between 30 milliseconds
and 9999 seconds with the ▲/▼buttons. The timer begins counting down when you
START. To display elapsed cycle time, move the pointer to Unitmed
UnitmedUnitmed
Unitmed, then press STOP;
elapsed cycle time is then displayed during HeatOn. (Ensure: 2button Start §2.2 when
using timer!)
…to quickly reset the Timer to 0.00 if indicated (
►)
At the bottom left corner of the screen, this is the actual RF output (always 0.0 when the
heat is turned off). When the output power is turned on, this displays the output in terms
of RF coil power or current. The output level can be shown in RF Amps or RF Watts
(press to toggle).
At the bottom right corner of the screen, the frequency at which the supply is heating is
shown. This is the resonant operating frequency and is the result of your coil in
combination with the heat station’s internal capacitance. (Note: You cannot ‘set’ this
frequency other than through your selection of heating coil.)
When Ready after first turning on the EASYHEAT, the frequency is displayed as 0 kHz.
During the first heat cycle (HeatOn), the frequency value shows you what the resonant
(most efficient heating) point is. When the heat is turned off, the display will show you
where it will begin to resonate on the next heat cycle - based on the recent heating cycle.
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.
Setpoint Timer
Output Freq
Setpoint Timer
Output
Freq
Setpoint Timer
Output
Freq

How Your EASYHEAT Works 17
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Status LEDs
This guide will help you understand the operation of your EASYHEAT.
●●


Ready
EASYHEAT is waiting to heat; no faults detected
Ready LED will flash when heat is off and the operator is in
the System Status page (heat can be turned on in this
condition).
Ready LED is off when the operator is in any other menu
page.
●


Ready + 

HeatOn
START command received, outputting power per settings.
Since both are lit output is within acceptable margins. It may
be possible to achieve a more efficient configuration.
for possible suggestion to improve operation; refer to §3
for further adjusting instructions
●●


HeatOn (Limit):
Unit heating, not meeting setpoint
*@display; output differs from setpoint by more than 2%
for suggested corrective step(s)
...
......
...ŵ
ŵŵ
ŵ(W overscored); displayed output power is outside a
preferred tolerance band. Increase tap for possible
improvements
!Cap
CapCap
Cap @display; you are attempting to adjust Setpoint above
safe limit for capacitors used. Reduce Setpoint
●●


Fault
Heating interrupted; fault detected; correction required
to Control zone, ►Status then for fault notice
AC Power; indicates EASYHEAT is ON; *see the Status screen for notices
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

How Your EASYHEAT Works
18
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). The unit
returns to Ready state. (STOP signal from front or rear panel always halts
induction heating)
Next
Use it to move the display pointer (►)
from one data field to the next. For
example, the display first looks like
this:
To program a heating time, press ►once; the
pointer is to the left of the ‘Untimed’ message.
Any following adjustments will apply to the
timer.
Up/Down
Within the Home zone, these are used to adjust Setpoint and Timer (indicated
with the display pointer).
Within the Control zone (below), use either button to ‘replay’ the start-up
screens (to review firmware version), to adjust the RF-Set figures or to display
Setup sub-fields.
To adjust Setpoint or Timer, you can press once to make a single-step adjustment, or you
can hold the button to scroll quickly to a new value.
Page
From within the Home zone, pressing this button moves to the Control zone
(see map) if the equipment is Ready. Pressing page during HeatOn displays
the internal temperatures and notices.
Within the Control zone, this button is used to select and exit the feature fields.
Home
This button takes you back to the Home zone, no matter where you have
navigated in the touch-pad map.
If you are already at the Home zone, pressing this button switches between
displayed output current (A) and displayed output Watts (W).
►0.0A Untimed
0.0A *0kHz
0.0A ►Untimed
0.0A *0kHz

How Your EASYHEAT Works 19
801-9309.doc
Navigation
This map will help you understand operation and programming your EASYHEAT:
Normal operation is from within the Home zone, where you:
•adjust setpoint and timer
•turn RF power on and off
•switch displayed units or
•move to the Control zone using 
The Control zone is where you:
•display and select Setup options (front or rear control, etc., below)
•display Status (internal temperature, Fault notices)
•construct and enact heating Profiles
•adjust for RF output stage configuration (tap settings, tank capacitor)
Each touch-pad button is represented in the map, showing the effect touching each
one has depending on your location in the map
Start From:
Language Choice:
Communication:
Contrast Adjust:
Lock Front Panel:
Alarm Limits:
Display Percent:
Start Type:
Control From:
System Options System Status
Adjust Profiles Heat Station
PrevFaults
ºF/ºC
Modify Cap
Modify Tap
Select Profiles
A B C D
Temperature,
Faults
Amps/
Watts
dis play ed
START
HEAT
STOP
HEAT
Setpoint Timer
Output Freq
Temps, Faults
adj
Home
Control

How Your EASYHEAT Works
20
Sta
rt from
►Front Panel
2
2. .2 2 C Co on nt tr ro ol l Z Zo on ne e
This is how you review or change operating characteristics of the EASYHEAT. Control
Zone is accessible only while heat is off.
From the Home zone, press , the Control Zone menu is shown. Use ►to select
from 4 sub-menus, detailed below (defaults underlined).
Once this screen is displayed, press ; use ▲/▼to select operating features; we present
the selections starting with the bottom of the list, working up...
Start From
Start FromStart From
Start From
Front: to START heating from the front panel
Rear: you attach your remote signaling source
(PLC, relays, etc.) to CTB1 at the rear and
START with those signals.
RS485 4 Wire: if ‘Communication = RS485 4
Wire’, below, select this to start heating with
serial command (STOP always works from front
or rear)
Language Choice
Language ChoiceLanguage Choice
Language Choice
English: select arrow for available language(s)
RS485 Baud rate
RS485 Baud rateRS485 Baud rate
RS485 Baud rate
38400: Use ►to select baud rate to be used for
communications.
RS485 Address
RS485 AddressRS485 Address
RS485 Address
1: Use ►to select and ▲/▼to adjust address. ►
to save. Address is used for communications, see §
3.3. ID is the SYS ID. See § 1.4
Menu Selection
►System Options
►




►
►
►
►
►
Language Choice
►English
RS485 Baud rate
►38400
RS485 Address
►1 D=nnnnn