Rimac DHI3-F1 Operating instructions

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Operating and Maintenance Manual, v1.4.01
INDUCTION HEATER
DHI3-F1

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CONTENTS
1INTRODUCTION.............................................................................................................................8
2SAFETY INSTRUCTIONS..................................................................................................................9
2.1 GENERAL RULES WHEN USING DHI3-F1.................................................................................... 9
2.2 INFORMATION SYMBOLS........................................................................................................ 11
2.3 SYMBOLS INDICATING HEALTH RISKS .................................................................................... 13
2.3.1 ELECTRIC SHOCK ............................................................................................................13
2.3.2 CAUTION! HOT SURFACE ................................................................................................14
2.3.3 RISK OF FIRE ....................................................................................................................14
2.4 SYMBOLS WARNING WHILE HANDLING THE DEVICE ............................................................ 15
2.4.1 SAFETY EQUIPMENT WHEN WORKING WITH THE DEVICE ................................................15
2.4.2 ELECTROMAGNETIC EFFECTS ..........................................................................................16
3PERIODIC INSPECTION AND MAINTENANCE .............................................................................18
4STORAGE ....................................................................................................................................19
5WARRANTY PROVISION..............................................................................................................20
6COMMISSIONING ......................................................................................................................22
6.1 UNPACKING AND FIRST START ........................................................................................................ 22
6.2 COOLANT REFILLING .................................................................................................................... 22

7ABOUT THE DEVICE AND HEATING ............................................................................................ 24
7.1 SUPPORTED TECHNOLOGIES...........................................................................................................24
7.1.1 DHCS3 - Dawell Heating Control System 3................................................................... 24
Technology developed by Dawell enabling controlled heating with multiple-pass real-time
control of various parameters, which is the heart of the device features. The heating can
thus be controlled in various modes, increasing its applicability and versatility. It can be
used in grids with poorer switchgear, where it does not trip circuit breakers etc. ................ 24
7.1.2 BIPT –Boost Induction Power Technology Enables increasing output power for better
and faster material heating. This technology finds application primarily in open coils and
heating various types of material. ........................................................................................... 24
7.1.3 DIPA - Dynamic Induction Power Adjust ...................................................................... 24
7.1.4 QST - Quiet Cooling Technology................................................................................... 24
7.1.5 URC - Universal Remote Control ................................................................................... 25
Support to universal remote device control, both analog and digital, or using a data bus,
enabling easy integration into production processes. ........................................................... 25
7.1.6 ACMS - Automatic Check And Monitor System .......................................................... 25
Combines features that check and verify device functionality and condition after
activation, and a feature that constantly supervises and monitors the heating running and
parameters for maximum device safety and reliability.......................................................... 25
7.1.7 DFU - Device Firmware Update .................................................................................... 25
Enables updating the firmware................................................................................................ 25
7.2 HEATING MODES AND THEIR APPLICATION .......................................................................................25
7.2.1 Field or burner power mode (CF) ................................................................................. 25
7.2.2 Controlled power mode (CP) ....................................................................................... 26

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7.2.3 Control to desired temperature (CT, optional) ............................................................27
7.3 CONTROLLED HEATING................................................................................................................. 27
7.3.1 Using the heating timer..................................................................................................27
7.3.2 Controlled heating based on set temperature profile ................................................27
7.4 REMOTE CONTROL AND INTEGRATION INTO PRODUCTION PROCESSES................................................. 27
8DEVICE CONTROLS.....................................................................................................................29
8.1 DESCRIPTION OF DEVICE COMPONENTS.......................................................................................... 29
8.1.1 Heating indicator lamp .................................................................................................30
8.1.2 Cooling and overheating indicator lamp ....................................................................30
8.1.3 REMOTE indicator lamp .................................................................................................31
8.1.4 ............................................................................................................................................31
8.2 ACTIVATING THE DEVICE ............................................................................................................... 31
8.3 STANDBY..................................................................................................................................... 31
8.4 HEATING TIMER ............................................................................................................................ 33
8.5 PROGRAM .................................................................................................................................. 34
8.6 INFO........................................................................................................................................... 36
8.6.1 P –Power transmitted ....................................................................................................38
8.6.2 Po –Output power.........................................................................................................38
8.6.3 PF –Power Factor...........................................................................................................38
8.6.4 Frequency „FrE“ .............................................................................................................39
8.6.5 Output current ...............................................................................................................39
8.6.6 Input current...................................................................................................................39

8.6.7 Input voltage ................................................................................................................. 39
8.6.8 Cooling temperature .................................................................................................... 39
8.6.9 Limitation........................................................................................................................ 39
8.6.10 Errors ........................................................................................................................... 40
8.7 SETTING.......................................................................................................................................40
8.7.1 “HC” Heating mode ...................................................................................................... 42
8.7.2 “Po L” Maximum output power .................................................................................... 42
8.7.3 “ic.L” Power line current limit ........................................................................................ 42
8.7.4 “FIL” Coolant filling and venting ................................................................................... 43
8.7.5 “CoL” Cooling settings .................................................................................................. 43
8.7.6 “RC” Remote control .................................................................................................... 43
8.7.7 FAC “Factory setting”.................................................................................................... 43
8.7.8 Firmware......................................................................................................................... 44
8.7.9 Unlock code .................................................................................................................. 44
9REMOTE CONTROL ..................................................................................................................... 45
9.1.1 Connector pinning ........................................................................................................ 45
9.1.2 Foot pedal connection ................................................................................................. 46
9.1.3 Control connection ON/OFF......................................................................................... 46
9.1.4 Analog remote control connection ............................................................................. 46
9.1.5 Digital remote control connection ............................................................................... 46
9.1.6 USB connection ............................................................................................................. 46
9.2 LIST OF ERROR MESSAGES ..............................................................................................................46
10 TECHNICAL PARAMETERS........................................................................................................... 48

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10.1 SUPPORTED FEATURES ................................................................................................................... 49
11 CERTIFICATES..............................................................................................................................50
12 USED DEVICE DISPOSAL .............................................................................................................51
13 WIRING DIAGRAM......................................................................................................................52
14 QUALITY CERTIFICATE.................................................................................................................53
15 WARRANTY SERVICING ..............................................................................................................54
16 WARRANTY CERTIFICATE ............................................................................................................55

1INTRODUCTION
Dear Customer, thank you for your trust and purchase of our product. Before
commissioning, please read carefully all the instructions contained in this Manual.
Instructions for use and maintenance shown herein have to be strictly observed for
optimum and lasting use.
We recommend, in your own interest, committing maintenance and any repairs to our
servicing organisation, since it has available the appropriate tools and specially trained staff.
All our machines and equipment are subject to long-term development; we therefore
reserve the right to modifications.

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2SAFETY INSTRUCTIONS
2.1
GENERAL RULES WHEN USING DHI3-F1
Symbols shown in this Manual warn and identify potential hazards when handling the
device.
-Do not leave DHI3-F1 unattended while it is turned on. Always deactivate DHI3-
F1 with the master switch when not using it for heating!
-Make sure that the power supply unit and the grip have sufficient air supply for
cooling. Make sure that the ventilation openings are clean and free of dust and
dirt, to not preclude flow of cooling air.
-Do not attempt to repair your DHI3-F1. The device contains no user-reparable
components with the exception of replaceable heating coils.
-The user is responsible for the system installation and use in accordance with
instructions shown in this Manual. The supplier is not liable for any damage due
to inexpert use and operation.
-Only persons appropriately trained and adequately qualified may work with the
device. Do not use the device under the influence of drugs, alcohol and
medication.
-Keep persons standing around and animals at a safe distance while working
with the device, including while the heated material is cooling down.

-Avoid working in rain, water and humid environments. Keep the working area
well ventilated and dry, clean and well lit.
SYMBOL
EXPLANATION
DANGER! Denotes a dangerous situation that will result in a
death or serious injury. The potential risks are shown under
the following symbols, or explained in the text.
Before plugging in your DHI3-F1, make sure the socket
voltage matches that on the product plate. If the socket
voltage does not match that shown on the type plate, it
can result in a serious hazard and damage to your DHI3-F1.
Do not exceed the working cycle of the DHI3-F1, being 1-2
minutes heating (on) and 2 minutes cooling (off). The main
device has overheating protection, but the heating coils
do not, so they may be damaged.

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2.2
INFORMATION SYMBOLS
The symbols shown below will guide you through this Manual and warn you of potential
risks.
If you see the symbol, be careful! Follow the instructions shown below to avoid the
dangers.
Read all the safety notifications and follow the instruction shown below.
You will find more safety instructions in Sections 2.3 –2.7.
SYMBOL
EXPLANATION
Risk of death by electrocution
IMPORTANT! Read this Manual carefully to gain information
about the device features. Inappropriate handling may
cause injuries to persons and damage to the device.

CAUTION! Hot surface! Risk of burns!
CAUTION! Risk of electric shock!
Risk of fire
Electromagnetic field risk
Do not use cardiac pacemakers, implanted devices and
watches or other metal objects.

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Always use! Protective goggles, protective masks and
protective gloves
2.3
SYMBOLS INDICATING HEALTH RISKS
2.3.1 ELECTRIC SHOCK
CAUTION! Never remove casing and do any activity with the induction
heater unless you have first disconnected the plug from the socket. Then
wait at least 1-2 minutes after unplugging it.
DO NOT WORK WITH THE DEVICE IN RAIN.
CAUTION! Any interventions in the electrical section have to be done by a
qualified electrician. There is a risk of electric shock during any
unauthorised servicing.

2.3.2 CAUTION! HOT SURFACE
CAUTION! Do not touch any objects located near the induction heater
unless you have checked that it has cooled down.
Do not touch the induction coil if it is activated and the strong magnetic
field and heating are turned on.
ALWAYS wear protective gloves or other protections when handling the
device as there is a risk of burns. Protective equipment is specified in
Chapter 2.4.
2.3.3 RISK OF FIRE

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Do not overheat parts.
Be careful about fire if the device is kept near one. Keep inflammable
substances outside the working area.
Do not put the device on, over or near inflammable surfaces.
Do not use the machine if it is near objects that may contain inflammable
particles of dust, gas, vapour or liquids. After completion of work with the
device, check the area to make sure everything is secure and there is no
risk of sparks, flames and fire.
2.4
SYMBOLS WARNING WHILE HANDLING THE DEVICE
2.4.1 SAFETY EQUIPMENT WHEN WORKING WITH THE DEVICE
Always wear protective goggles or face mask when using the DHI3-F1.

Use of the device may produce dangerous waste gases from burning of old
paints, lubricants, sealants, glues, etc. These exhausts may be toxic. Always
use adequate protective masks or respirators.
Always use protective gloves with adequate thermal resistance when working
with the device. The high temperatures produced by using the DHI3-F1 may
cause serious burns on contact with the heated part.
2.4.2 ELECTROMAGNETIC EFFECTS
The electromagnetic field (EMF) may affect implanted medical devices. The
device is not intended to be used by users of cardiac pacemakers or other
implanted medical devices.

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Persons with other metallic or electronic surgical implants are not allowed to
work with the DHI3-F1 and have to keep a safe distance of at least 1 m from
the device.
When working with the DHI3-F1, do not wear any metal objects such as
jewels, rings, watches, necklaces, identification plates, belt buckles, piercing
or clothes with metal components such as metal rivets, buttons, zip fasteners,
etc.
The device can heat these metal objects very fast and thus cause serious
burns or even ignition of clothes!
! Users of these devices should immediately consult their medical doctor to avoid potential
troubles connected with them while handling the device.

3PERIODIC INSPECTION AND MAINTENANCE
Scheduling device maintenance has to consider the degree and circumstances of device use.
Considerate use and preventive maintenance help prevent needless defects and
malfunctions. Perform checks as per standards and law in force. Only workers with adequate
electrical engineering qualifications may carry out any jobs on the device.
WARNING!!!
Any handling of the power supply, including maintenance, requires its disconnection from the
power line. To prevent injuries, always disconnect the power cable and wait at least 2 minutes
before removing the casing. Discharge the capacitor circuits before any further work.
Periodic maintenance includes cleaning the device every half a year:
1. Disconnect the device plug from the socket and wait about 2 minutes (the capacitors
inside the device will discharge). Then remove the upper device casing.
2. Clean all dirty power electric connections and tighten any loose ones.
3. Clean the internal device parts (coolers in particular) to remove dust and dirt –for example
using a soft brush and vacuum cleaner.
4. The upper casing has to be earthed –remember to connect the yellow-and-green
earthing wire before screwing it on.
5. After maintenance, carry out safety measurements as per standards in force.
Note: Never use solvents or thinners (e.g., acetone), because they may damage insulation,
plastic parts and lettering on the front panel!!

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4STORAGE
The device has to be stored in a clean and dry room. Protect the device from rain and direct
sunshine.
After heating completion, leave the device switched on for 10 more minutes - it will be cooled
down by fans until it is cold, then it deactivates the fans. After that, turn it off using the master
switch and disconnect it from the power line.
If you disconnect the device immediately, leave it and all the working coils to cool down for at
least 15 minutes.

5WARRANTY PROVISION
1. Unless otherwise specified, the warranty period for devices is set by the manufacturer at 12
months from the date of sale to the buyer.
2. When making a claim for warranty repair, the warranty certificate has to be shown; it is
only valid if it bears the date of sale, serial number, stamp of the shop and the seller’s
signature, confirming proper demonstration and explanation of the device features.
3. The warranty period will be extended by the time for which the device is in warranty repair.
If the repair finds no defects falling under the warranty, the device owner shall pay the
costs of the servicing technician’s work.
4. The warranty servicing covers defects occurring during the warranty period demonstrably
due to flawed design, flawed workmanship or inappropriate material. Such defects will be
repaired by the manufacturer free of charge. Complaints shall be made by the user with
the device manufacturer; the place of performance is the manufacturer’s registered
office.
5. The warranty does not cover defects caused by inexpert handling, overloading, use of
wrong accessories, or interventions by unauthorised persons, natural wear and tear, or
damage during transport. Recognised defects exclude damage occurring due to
inadequate care of neglected maintenance, non-adherence to rules specified in the