Ultraflex Easy Melt Air 1G User manual

UPT Series Easy Melt
Operation Manual
Version 1.2 1
www.ultraflexpower.com
Desktop Melter
Product Model:
Easy Melt Air 1G - Air cooled Desktop Melter, 1kg Gold
Part Number:
0UPT-016-600-00
Operation Manual

UPT Series Easy Melt
Operation Manual
Version 1.2 2
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TABLE OF CONTENTS:
1 GETTING STARTE GUI E ................................................................................................................................... 3
1.1 SAFETY INSTRUCTION .............................................................................................................................. 3
1.1.1 IMPORTANT NOTES ............................................................................................................................ 3
1.1.2 SAFETY PRECAUTIONS ........................................................................................................................ 4
1.1.2.1 ELECTRICAL SHOCK HAZARDS ........................................................................................................ 4
1.1.2.2 GROUNDING ................................................................................................................................. 4
1.1.2.3 SAFETY AND PRECAUTION SYMBOLS USED IN THIS MANUAL ......................................................... 5
1.1.2.4 MAGNETIC FIELD ........................................................................................................................... 5
1.2 INSTALLATION AN START UP ................................................................................................................. 5
1.2.1 INSTALLATION PROCE URE ................................................................................................................ 5
1.2.2 UNPACKING AN INSPECTION ............................................................................................................ 6
1.2.3 SELECTING THE EVICE SITE ............................................................................................................... 6
1.2.4 COOLING REQUIREMENTS .................................................................................................................. 6
1.2.5 AC INPUT CONNECTION ..................................................................................................................... 6
1.2.6 START-UP ........................................................................................................................................... 7
1.2.7 USING THE MACHINE ......................................................................................................................... 7
1.3 MAINTENANCE........................................................................................................................................ 8
1.3.1 SCHE ULING ........................................................................................................................................... 8
1.3.2 PERSONNEL ........................................................................................................................................ 8
1.3.3 INSPECTION AN MAINTENANCE PROCE URE ................................................................................... 8
2 PRO UCT SPECIFICATIONS AN FEATURES ......................................................................................................... 9
2.1 PRO UCT SPECIFICATIONS ...................................................................................................................... 9
2.1.1 OVERVIEW ......................................................................................................................................... 9
2.1.2 EVICE SPECIFICATIONS TABLE ........................................................................................................... 9
2.1.3 CONNECTION IAGRAM ................................................................................................................... 10
2.2 CONTROLS AN OPERATION ................................................................................................................. 11
2.2.1 CONTROL PANEL OVERVIEW ............................................................................................................ 11
2.2.2 CONTROLS AN IN ICATORS ........................................................................................................... 11
2.2.3 REGULATION MO ES AN SYSTEM STATUSES .................................................................................. 12
2.2.4 MENUS AN NAVIGATION ............................................................................................................... 13
2.2.4.1 Main M nu Navigation ................................................................................................................ 13
2.2.4.2 H at ON M nu Navigation .......................................................................................................... 13
2.2.4.3 SYSTEM MENU Navigation .......................................................................................................... 15
2.2.4.4 EXTENDED MENU Navigation ...................................................................................................... 16
2.2.5 CONTROL MO ES............................................................................................................................. 19
3 TUNING AN TROUBLESHOOTING .................................................................................................................... 19
3.1 LOA TUNING GUI E ............................................................................................................................ 19
3.2 SERVICE AN TROUBLESHOOTING ........................................................................................................ 19
3.3.1 ERROR MESSAGES ............................................................................................................................ 19
3.3.2 GENERAL .......................................................................................................................................... 21
3.3.3 SERVICE CONTACT INFORMATION .................................................................................................... 21
Appendix A: RECOMMEN E SPARE PARTS KIT ................................................................................................... 22
Appendix B: ACCESSORIES ................................................................................................................................... 22

UPT Series Easy Melt
Operation Manual
Version 1.2 3
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1GETTING STA TED GUIDE
1.1 SAFETY INST UCTION
1.1.1 IMPO TANT NOTES
1. This manual is valid only for the Model and the associated Revision number(s) specified in the cover sheet of this
manual. A Change Page may be included at the end of the manual. All applicable changes are documented with
reference to the equipment Revision and Serial number. Before using this Instruction Manual, check your equipment
nameplate to identify your Model and Revision number. If in doubt, contact your nearest Ultraflex Representative;
2. This document contains information proprietary to Ultraflex. All rights are reserved. No part of this document
may be reproduced, transmitted, processed or recorded by any means or form, electronic, mechanical, photographic
or otherwise, nor be released to any third party without the express written consent of Ultraflex;
3. In this document period “.” will be used as a decimal point delimiter.
4. ata subject to change without notice;
5. All Information contained in this manual is the latest information available at the time of printing. The right is
reserved to make changes at anytime without notice. Ultraflex makes no warranty of any kind with regard to this
material and assumes no responsibility for any errors that may occur in this manual;
6. Safety First!
YOU AND NOT THIS MANUAL A E EPONSIBLE FO ALL SAFETY
P ECAUTIONS
This manual is for reference purposes only. Personnel should be trained on proper operation of this equipment
before using. Only authorized personnel may perform any troubleshooting or repair on any ULTRAFLEX
manufactured equipment. Failure to comply will void warranty.
Please, contact the ULTRAFLEX Service epartment before servicing any ULTRAFLEX equipment.
Lethal voltages may be present in equipment surrounding and/or connected to this equipment. Read the following
warnings carefully and study this entire manual before operating the system. Failure to observe warnings may result
in equipment damage, serious personal injury, or death.
If the equipment is used in a manner not specified by this manual, the protection provided by the equipment may be
compromised and damage to the unit may occur.
1. Only qualified persons who have been trained in the operation of this equipment and are familiar with the
technology should be permitted to operate the system;
2. Installation, assembly, inspection maintenance and servicing are to be performed by authorized personnel only;
3. Always have the Power Supply completely powered OFF and locked out before performing any service, inspection
or maintenance;
4. Even with the Power Supply OFF, live voltages still exist within the cabinet. Always power OFF and lock out the
external power source to ensure no one can accidentally energize it;
5. Ensure that all external wiring conforms to applicable codes;
6. Obey all warnings and use good common sense;

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Operation Manual
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1.1.2 SAFETY P ECAUTIONS
1.1.2.1 ELECT ICAL SHOCK HAZA DS
This manual is written for personnel familiar with the technology pertaining to the operation of induction heating
equipment. Such personnel should be thoroughly familiar with the hazards associated with this equipment and
electrical equipment in general, and they should have received proper safety procedure training.
Hazardous voltages are present within this product during normal operation. The product should never be operated
with the cover removed unless equivalent protection of the operator from accidental contact with hazardous
internal voltages is provided. Operators must be trained in its use and exercise caution as well as common sense
during use to prevent accidental shock.
THERE ARE NO OPERATOR SERVICEABLE PARTS OR ADJUSTMENTS WITHIN THE PRODUCT
ENCLOSURE. REFER ALL SERVICING TO TRAINED SERVICE TECHNICIAN.
SOURCE POWER MUST BE REMOVED FROM THE PRODUCT PRIOR TO PERFORMING AN
SERVICING.
THIS PRODUCT IS DESIGNED FOR USE WITH NOMINAL A-C MAINS VOLTAGES INDICATED ON
THE RATING NAMEPLATE.
1.1.2.2 G OUNDING
This product is a Class 1 device which utilizes protective grounding to earth to ensure operator‘s safety.
PROTECTIVE EARTHING CONDUCTOR TERMINAL -This symbol indicates the point on the
product to which the protective grounding conductor must be attached.
EARTH (GROUND) TERMINAL -This symbol is used to indicate a point which is connected to the
PROTECTIVE EARTHING TERMINAL. The component installer/assembler must ensure that this
point is connected to the PROTECTIVE EARTHING TERMINAL.
CHASSIS TERMINAL -This symbol indicates frame (chassis) connection, which is supplied as a
point of convenience for performance purposes. This is not to be confused with the protective
grounding point, and may not be used in place of it.

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Operation Manual
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1.1.2.3 SAFETY AND P ECAUTION SYMBOLS USED IN THIS MANUAL
A WARNING symbol alerts you to a hazard that may result in equipment damage, personal injury, or
death. Carefully read the instructions provided WARNING and follow all safety precautions.
A CAUTION symbol alerts you that the system may not operate as expected if instructions are not
followed.
1.1.2.4 MAGNETIC FIELD
WARNING: MAGNETIC FIELD!
CAN BE HARMFUL TO PACEMAKER WEARERS AND PEOPLE WITH METALLIC IMPLANTS!
PACEMAKER AND METALLIC IMPLANTS WEARERS STA BACK 30sm (12in)!
1.2 INSTALLATION AND STA T UP
1.2.1 INSTALLATION P OCEDU E
The installation procedure consists of the following steps:
•Unpacking the equipment;
•Selecting the site where the equipment will be used;
•Connecting the Heat Station (if remote Heat Station is provided);
•Connecting accessories or interfacing the system with other controls (if necessary);
•Completing the Power and Ground/Earth connections.
POWER AND GROUND/EARTH CONNECTIONS MUST BE MADE LAST. FAILURE TO DO SO WILL
CREATE A HAZARDOUS CONDITION THAT MA RESULT IN EQUIPMENT DAMAGE, PERSONAL
INJUR , OR DEATH.
NOTE: Ultraflex has a staff of field engineers who are available to supervise the installation of the equipment. If
installation service is required, contact our Technical Service Department for additional information.
Provisions for facility electrical power service are customer furnished. Requesting field engineering assistance before
customer furnished provisions are installed at the equipment site could delay equipment installation and cause
unnecessary expense.

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Operation Manual
Version 1.2 6
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1.2.2 UNPACKING AND INSPECTION
This equipment has been thoroughly inspected and tested prior to packing and is ready for operation. After careful
unpacking, visually inspect for shipping damage BEFORE attempting to operate. If any indication of damage is found,
file an immediate claim with the responsible transport service and advise your sales representative.
INSPECT EQUIPMENT BEFORE INSTALLING. DAMAGED EQUIPMENT MA RESULT IN IMPROPER
OPERATION AND CREATE A HAZARDOUS CONDITION RESULTING IN PERSONAL INJUR OR
DEATH.
THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE CAUSED IN SHIPMENT INCLUDING CONCEALED
DAMAGE.
1.2.3 SELECTING THE DEVICE SITE
Consider the following when choosing a location for the device:
•Make sure the system is installed in a debris free zone;
•The device has to be connected to a power source;
•Make sure the device is easily accessible by the operator;
•evice has to be seated on a mechanically secure surface;
1.2.4 COOLING EQUI EMENTS
The power transistors and rectifiers in the Power Supply are maintained within their safe operating temperature
range by means of forced air cooling (fans). The fan inlets must be kept clean from obstructions in order to insure
proper air circulation. If installed in confined spaces, care must be taken that the ambient temperature (the
temperature of the space immediately surrounding the Power Supply, does not rise above the limit specified as 40°C.
Periodic cleaning of the Power Supply exterior is recommended.
1.2.5 AC INPUT CONNECTION
The Power supply connects to the power network through a 6 ft (1.80m), power cord (supplied). Additional fuse or
circuit breaker and residual current circuit breaker on that power branch is a good choice since it will provide extra
protection in addition to the unit’s internal protection. A mechanical switch is also recommended within the
operator‘s range and vision and possibly closer to the Power Supply.
Only trained personnel should open the unit cover and operate the breakers.

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Operation Manual
Version 1.2 7
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Table 1.1: Wiring Color Code
Color 1-Phase Connection 3-Phase Connection
Brown
Line 1
Blue
Neutral
or Line 2
Green/Yellow
Protective Earth
INSPECT EQUIPMENT BEFORE INSTALLING. DAMAGED EQUIPMENT MA RESULT IN IMPROPER
OPERATION AND CREATE A HAZARDOUS CONDITION RESULTING IN PERSONAL INJUR OR
DEATH.
THE CARRIER IS RESPONSIBLE FOR ALL DAMAGE CAUSED IN SHIPMENT INCLUDING CONCEALED
DAMAGE.
NOTE: LOCAL CODES MA HAVE STRINGENT REQUIREMENTS. IT IS THE CUSTOMER‘S
RESPONSIBILIT TO BE FAMILIAR WITH AND TO COMPL WITH ALL APPLICABLE CODES
CONCERNING CONDUCTOR RATINGS AND WIRING PROCEDURES. AN ELECTRICIAN FAMILIAR
WITH THE LOCAL REGULATIONS SHOULD DETERMINE PROPER WIRING CONNECTIONS.
1.2.6 STA T-UP
1. Connect the AC and ground connections as described in Section 1.2.5;
2. Turn the Power Switch on to power the system. Check for any Fault or Alarm messages. If the status screen
shows “100% Power” message, then the system is ready for operation.
See Section 2 of this Manual fo Connections Diag ams.
1.2.7 USING THE MACHINE
1. Connect the machine to the electric supply 220/230 VAC – single phase;
2. Crucible. Check that your crucible is good enough to make a melting. A too much used crucible can make the
casting very slow. Check also that the bottom is not too thin, you risk that it brakes during the melting causing the
metal going out.
3. Place the crucible in the melting chamber. The purpose of the thermocouple is to read the temperature of the
induction coil in order to protect it from overheating.
4. Switch on the machine pressing the main switch (fig. 2.2-2) positioned on the back of the machine;
5. On the control panel you have the possibility to adjust 2 parameters:
- Power. This parameter determines how fast the melting will be done. We suggest to use 100 % power;
- Time. This timer can be set in 2 states – OFF or time in minutes 1 – 30. If the time is set (1 – 30 min) after starting
melting cycle, the timer will start to count down. When the set time expires, melting cycle stops. The purpose of this
timer is “time out“ for heat on. If you do not like to use the timer, set it in “OFF” state.

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Operation Manual
Version 1.2 8
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6. Choice of parameters. In order to choose the parameter, push the “SELECT” (fig. 2.3-10) button. The
corresponding red LE (fig. 2.3-6, 7, 8) will flash and shows the parameter you want to modify. With the arrow
buttons (fig. 2.3-9) you can adjust needed value and check it on the display (fig 2.5-5).
7. Melting. Put the metal into the crucible and push the “START” (fig. 2.3-2) button. The green LE (fig. 2.3-4) will
flash and machine will start to heat at previously set power level. Output power level can be changed during melting
cycle using arrow buttons.
8. The heating cycle can be stopped at any time by pressing “STOP” button (fig. 2.3-1).
9. If something is wrong the machine will go in “ERROR” state and the red LE (fig. 2.3-3) will flash. If the reason for
alarm condition is removed, you can escape “ERROR” state by pressing “STOP” button (fig. 2.3-1).
1.3 MAINTENANCE
1.3.1 SCHEDULING
The Power Supply is not designed for continuous operation. Every “HEAT ON” cycle must be followed by at least 5
minutes “HEAT OFF” period with working cooling fans. The frequency of any maintenance program is a function of
environment, degree of equipment use, and operator experience.
1.3.2 PE SONNEL
Qualified personnel must perform inspection and maintenance procedures only. Personnel must read and be
thoroughly familiar with all safety precautions discussed in this manual.
1.3.3 INSPECTION AND MAINTENANCE P OCEDU E
The following describes inspection procedures to be performed on a daily, weekly, and monthly basis.
Daily/Weekly Inspection: It is good practice to do a quick visual inspection of the unit, wiring and connections on a
daily and/or weekly basis. Report any apparent changes in performance to responsible personnel so that potential
problems can be investigated.
Monthly Inspection:
Perform the following on a monthly basis:
1. Ensure all wiring connections are secure. Visually inspect for any wear on cabling;
2. Verify that none of the enclosure hardware has become loose;
3. Remove any build-up debris that may occur around the fan inlet using a cloth or a vacuum cleaner. Using of
compressed air is not recommended;
4. Wipe the Control Panel with a damp cloth to remove any dirt, prints or spots;
5. Wipe the enclosure down with a damp cloth or paint friendly cleaner, if desired.

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Operation Manual
Version 1.2 9
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2P ODUCT SPECIFICATIONS AND FEATU ES
2.1 P ODUCT SPECIFICATIONS
2.1.1 OVE VIEW
The 0UPT-016-600-00 is an induction heating system designed to work only with a coil, supplied with the unit. It
consists of two main parts placed into the same cabinet. They are:
1. Power supply – generates RF power to supply the output circuit.
2. Heat Station – tank capacitor, induction coil, matching transformer (embedded and cannot work alone).
Heat Station – It is a part of the device placed into the same cabinet with HF power supply.
The Heat station consists of an output matching transformer with fixed transformer ratio, air cooled tank capacitor
assembly and terminals for connecting the induction coil.
The unit is digitally controlled through a control panel located on the front panel of device.
Figu e 2.1 Ove all Device Dimensions (in mm)
Notes:
1) A tool is required to gain access to the Power Supply. This is to prevent accidental exposure to the internal high
voltages.
2) See section Appendix B of this Manual for optional equipment and Accessories.
2.1.2 DEVICE SPECIFICATIONS TABLE
Table 2.1 Easy Melt Ai 1G Specifications Table
SPECIFICATIONS RATING/DESCRIPTION CONDITION
INPUT
AC Voltage range 230 VAC (±10%) Single Phase
Line Frequency 50/60 Hz
Absorbed Power maximum 2.8kW @ 230 VAC ±10%
Input Current maximum (RMS) 21 A @ 230 VAC -10%
Input Power maximum 4.3 kVA @ 230 VAC ±10%

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Operation Manual
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Efficiency minimum 88% @ full load
OUTPUT
Control Modes Constant Power with voltage and current limit
Output Current maximum 15 A (sine wave) @ 100% current reference
Output Voltage maximum 250V RMS @ 230 VAC ±10% Input
Output Frequency Range
64 kHz ± 1 kHz No load
73 k
Hz
± 1 kHz
With empty crucible
73 k
Hz
± 1 kHz
With full crucible
Output Transformer Ratio N
tr
10:1 fixed transformer ratio
Tank Capacitor 1 x 3CFM-105-001-01 UPT-120, 200kVA, 1.2µF
Working Coil with built
-
in
thermocouple 1ASM-016-601-00 i=70mm, inner surface with cement
Timer Resolution 1min/step 1 – 30 min.
PROTECTION
Over-current 45 A (Peak) Inverter output current
Over-temperature heat sink 60°C Reset by depressing STOP
MISCELLANEOUS
Temperature Ranges 32˚F (0°C) to + 104˚F (40°C) Operating
-4˚F (-20°C) to + 150˚F (65°C) Storage
Humidity range 0 to 95% RH Non-condensing Operating &Storage
PH SICAL
Module imensions
W x x H in/(cm)
18 x 15.4 x 7.2
(45.7 x 39.1x 18.1) Overall dimensions with feet
Weight 30.9 lb (14 kg) Net weight
2.1.3 CONNECTION DIAG AM
Figu e 2.2 Rea Panel Connections
1
2
3