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.