Powell 3-135/400-3W User manual

Induction Power Supplies
3kW; 135 – 400kHz
(Integral Heat Station)
User’s Guide
Model 3-135/400-3
Model 3-135/400-3W
Rev E 12/1/04

Table of Contents
1. SPECIFICATIONS AND FEATURES....................................................................................3
1.1. Output...........................................................................................................................3
1.2. Input..............................................................................................................................3
1.3. Physical ........................................................................................................................3
1.4. Front panel controls and indicators...............................................................................4
1.5. Internal heat station......................................................................................................4
1.6. Protection......................................................................................................................5
1.7. Load..............................................................................................................................5
1.8. Cooling Water……………………………………………………………………………….…5
2. GETTING STARTED .............................................................................................................6
2.1. Safety Warnings ...........................................................................................................6
2.2. Set-Up ..........................................................................................................................6
3. CONNECTIONS.....................................................................................................................7
3.1. Load..............................................................................................................................7
3.2. 230VAC input voltage...................................................................................................7
3.3. Circuit Breaker..............................................................................................................8
3.4. Terminal Block # 1........................................................................................................8
3.5. Terminal Block # 2........................................................................................................8
4. FRONT PANEL OPERATION ...............................................................................................9
4.1. Limit and trip indicators.................................................................................................9
4.2. Heat ON/OFF indicators. ............................................................................................10
4.3. Program status indicators...........................................................................................10
4.4. Voltage, Current and Frequency Indicators. ...............................................................10
4.5. Reset Button...............................................................................................................10
4.6. Heat switch.................................................................................................................10
4.7. Power Pot...................................................................................................................10
4.8. MODE switch..............................................................................................................11
4.9. E-Stop button..............................................................................................................11
4.10. Program buttons.......................................................................................................11
4.11. Power Display Indicator............................................................................................11
4.12. Start frequency adjustment.......................................................................................11
4.13. Feedback selection...................................................................................................12
5. PROGRAMMING IN AUTO MODE......................................................................................13
5.1. Entering a program.....................................................................................................13
5.2. Running a program.....................................................................................................14
5.3. Enabling external connections....................................................................................14
6. LOAD STATION TUNING....................................................................................................15
6.1. Tuning.........................................................................................................................15
6.2. Changing the heat station components. .....................................................................16
7. APPENDIX A: USER INTERFACE......................................................................................17
7.1. Terminal Block 1.........................................................................................................17
7.2. Terminal Block 2.........................................................................................................17
8. APPENDIX B: TUNING EXAMPLES................................................................................18
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1. Specifications and features
1.1. Output
Maximum Power 3kW1
Maximum Apparent Power 6.6kVA @ 230V input
Minimum Power Factor 0.50 @ 230 V input
Duty Cycle 100%
Maximum Voltage 350V rms 2
Frequency 135kHz to 400kHz
Maximum Response Time 0.1s3
Minimum Allowed OFF-Time 0.5s
1.2. Input
AC line-to-line voltage 208V – 240V ±10%, 50 to 60Hz
AC line current 14.5A @ 230V
AC power 3.6kVA
1.3. Physical
Dimensions: Length
Width
Height
20.5in (521mm)
11.7in (297mm)
12.7in (323mm)
Weight 43.5lb (20kg)
13kW is output power. 3.6kVA input power allows for losses in the power supply.
2Limited by rating of resonant capacitors.
3When using the adjustable start-frequency feature.
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1.4. Front panel controls and indicators
LED Indicators
Yellow indicator for power limit. Yellow indicator for voltage limit.
Yellow or red indicator (dual color) for
inverter current limit or trip respectively.
Yellow or red indicator (dual color) for
frequency limit or trip respectively.
Individual red indicators for door,
temperature, flow and/or auxiliary
interlock trips.
Numeric Displays Run time read-outs for output voltage,
inverter current and frequency
Power Meter (0-100%)
Job number (Auto mode)
Step (Auto mode)
Step Time (Auto mode)
Elapsed time (Manual and Auto mode)
Controls – Manual Mode Rocker switch for output power
ON/OFF.
Single turn knob for power level.
(Manual mode)
Pushbutton to reset trips.
Rocker switch for manual or auto
(programmed) operation.
Emergency stop button.
Freq button to select start frequency
Controls – Programmed Mode Program, Job, Step, Freq, Pwr,
Time/Freq, Clear and Enter buttons for
programming automatic mode
operation.
1.5. Internal heat station
Resonant capacitors Two 660nF, 350V capacitors supplied.
Series inductor Adjustable for load matching.
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1.6. Protection
Power Limited to 3kW in any feedback
configuration
Inverter output current Limited to 70A peak. Short circuit
protected.
Resonant capacitor voltage Limited to 350V rms
Line current 20A Circuit breaker
Temperature and cooling Air-cooling provide by three fans.
Heatsink temperature switch for
protection.
Safety Interlocks Emergency stop button or door switch
opens the main circuit breaker.
1.7. Load
Quality factor of load Will operate with any load Q (including
resistive loads), provided that the
output frequency and voltage is within
the specifications.
1.8. Cooling Water
Maximum pressure 100PSI (690kPa)
Minimum differential pressure 30PSI (207kPa)
Minimum water flow .5GPM (0.032l/s)
Maximum inlet water temperature 105°F (41°C)
Minimum water resistivity 590Ω.in (1500Ω.cm)
Supply hose location Back of Cabinet
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2. Getting started
2.1. Safety Warnings
Have all operation, maintenance and servicing performed by qualified personnel only.
1. Read this operation manual completely before using the power supply.
2. Induction heating can be dangerous. Obey all warnings on unit and in manual.
3. Do not touch live electrical parts. In operation, this means the output connectors,
the work coil, the work piece, and any bus work or cabling connecting them.
WARNING: These symbols, placed at the outputs of the
power supply, warn of the electric shock hazard there
and RF burn hazard at the outputs when the unit is
operating.
Disconnect input power before installing or servicing
this unit. The door interlock will open the breaker if the
cover is removed. However, the input AC voltage is live
at the top of the main circuit breaker.
2.2. Set-Up
The following is a list of steps describing the required actions to get the power supply set up.
1. Loosen the two quarter turn fasteners and remove the cover from the unit. Check for any
visual damage that could have happened during shipment. Check all plug-in connectors of
PCBs.
2. Connect the heating coil to the output of the unit (see section 3.1. on page 7).
3. Read section 4. on page 9 to become familiar with the front panel controls.
WARNING: Make sure that the
power is locked out before
connecting AC power to the unit.
Connect only 208-240VAC.
4. Ensure that the circuit breaker (identified by →in Figure 1) on the unit is in the OFF
position. Connect the power cord to a 230V single phase power source as described in
section 3.2. on page 7.
5. Perform the tuning of the heat station, as described in section 6.1. on page 15.
6. The unit is now ready for operation, and can either be controlled by the front panel (control
selection switches in “INT” position), or by external (control selection switches in “EXT”
position.
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3. Connections
This section gives a description of the required steps to connect the load, input voltage and
what connections to make to run the unit remotely.
1Output for mounting of heating coil
2Water input connection
3Water output connection
4Terminal Block # 1
5Terminal Block # 2
6Power cord for connection to supply voltage (plug not supplied)
Figure 1: Terminal blocks, circuit breaker, load and input voltage connections.
3.1. Load
Mount the heating coil to the side of the unit (see 1in Figure 1) using four 10-32 non-magnetic
(e.g. brass) screws. For most applications, a water cooled coil is necessary. If a flow switch is
used in the water path, it can be connected to Pins 4 & 5 of Terminal Block # 2. See Appendix
A for more details.
3.2. 230VAC input voltage
The unit is supplied with a 6 foot long cord (see 2in Figure 1). Install a single phase grounded
locking plug on the power cord. Connect the plug to an appropriate supply voltage outlet
socket. Note the requirements of the supply voltage given in section 1.2. on page 3. Ensure
that a proper safety ground is connected to the ground terminal of the three-wire socket.
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3.3. Circuit Breaker
The circuit breaker (see 3in Figure 1 on page 7) is the is equipped with a shunt trip which will
shut off the power if the cover is removed from the unit, or if the E-Stop switch is pressed.
3.4. Terminal Block # 1
The top three terminals of Terminal Block # 1 can be utilized for remote power reference..
(see 4in Figure 1 on page 7). The lower three terminals can be used to interface the power
supply with a computer. APPENDIX A: User Interface on page 17 explains the connections in
more detail.
3.5. Terminal Block # 2
Heat On, E-Stop, Auxiliary Interlock, and Reset functions can be run remotely from this
terminal block. There are also relay contacts for Heat On, Power Supply Fault and Power
Supply ready. APPENDIX A: User Interface on page 17 explains the connections in more
detail.
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4. Front panel operation
This section identifies and describes the various parts of the front panel.
1) Limit and trip LED
2) Heat On/Off LEDs
3) Program Indicators
4) Volt, Curr and Freq Indicators
5) Reset button
6) Heat switch
7) Power Knob
8) Mode Switch
9) E-Stop Switch
10) Program Buttons
11) Power Indicator
Figure 2: Front panel layout for model 3-135/400-3.
4.1. Limit and trip indicators.
Identified by 1in Figure 2 on page 9.
Limit indicators: These indicators are yellow in color and are lit when the heat station is not
properly tuned. The power output of the unit is limited below the desired level set by the power
knob or remote pendant. There are four limit indicators:
•POWER: If lit the power is being limited at 3kW.
•VOLT: If lit the capacitor voltage is being limited at 350V rms.
•FREQ: If lit the circuit is being limited at the resonant frequency of the resonant tank.
•CURRENT: If lit the inverter current is being limited at 70A peak. (Note: The load coil
current could be much higher than 70A peak).
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If any limit indicators are lit, the heat station components needs to be adjusted to obtain the
required power (see section 6.1. on page 15).
Trip indicators: These indicators are red in color and are lit if the unit is tripped. No power is
being delivered to the load and the heat OFF indicator will be lit. There are six trip indicators:
•FREQ: The circuit momentarily operated below the resonant frequency due to a short in the
load or heat station component or poor tuning of the heat station components.
•CURRENT: The inverter current momentarily exceeded 70A due to a short in the load or
heat station component of poor tuning of the heat station components.
•DOOR: Indicates that the cover of the unit is not replaced.
•TEMP: Indicates that the temperature of the heatsink has exceeded 85°C.
•FLOW: Not used on the 3kW power supply.
•AUX: An auxiliary interlock wired to the unit has tripped it, or the input AC voltage has
dropped.
4.2. Heat ON/OFF indicators.
These LEDs show whether the power supply is generating output or is off. (identified by din
Figure 2 on page 9).
4.3. Program status indicators.
Identified by 2in Figure 2 on page 9. These read-outs display the programs status when using
the AUTO mode. The STEP TIME indicator display minutes and the ELAPSED TIME indicator
displays seconds during manual mode operation.
4.4. Voltage, Current and Frequency Indicators.
Identified by 3in Figure 2 on page 9. These read-outs display the output voltage, the inverter
current and the operating frequency when the power supply is operating.
4.5. Reset Button
Identified by gin Figure 2 on page 9. This button is used to clear the fault indicators if a run-
time or interlock trip has occurred. Depressing the button will light the limit and trip indicators
and clear the latch for the fault indicator. If the LED does not go out, then the reason for the
fault is still present.
4.6. Heat switch
Identified by hFigure 2 on page 9. When the power supply is energized, and no fault
indicators are lit, putting this switch in the ON (I) position will start the power supply delivering
heat. When moved back to the OFF (O) position, the heating will be terminated. While in
AUTO mode, the ON position initiates the heat cycle. Putting the HEAT switch in the OFF
position will terminate the heat cycle.
4.7. Power Pot
Identified by iin Figure 2 on page 9. The power pot sets the requested power level as
indicated by the POWER read-out. The level of power feedback is indicated by the percentage
of the LED ring around the POWER POT that is illuminated. This pot is disabled during AUTO
mode operation.
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