PPSTinc 12.5-135/400 User manual

Induction Power Supplies

12.5KW; 135 – 400 KHz

LCD Display

(Integral Heat Station)

User’s Guide

Model 12.5-135/400

05/08

Rev D

1. Specifications and features...................................................................................... 3

2. Getting started........................................................................................................... 6

3. Connections .............................................................................................................. 8

4. Front panel description and operation.................................................................. 10

5. Programming and Status monitor ......................................................................... 16

6. Load station tuning. ................................................................................................ 22

7. APPENDIX A: USER INTERFACE........................................................................... 25

8. Layout.………………………………………………………………………………………27

9. Finding dew point…………………………………………………………………………28

1. Specifications and features

1.1. Output

Maximum Power 12.5kW1

Maximum Apparent Power 25kVA @ 240V input

Minimum Power Factor 0.5 @ 480V input

Duty Cycle 100%

Maximum Voltage 500V 2

Power Transformers (6) 2 :1

Frequency Range 135kHz to 400kHz

Maximum response time 0.1s3

Minimum Allowed OFF-Time 0.5s

1.2. Input

AC line-to-line voltage 240V  10%, 3



, 50 to 60Hz

AC line current 35A @ 240V

AC power 14.5kVA

1.3. Physical

Dimensions: Depth

Width

Height

16in (41cm)

20in (51cm)

43.75in (111cm)

Weight 275lb (125kg) approximately

1 Inverter output power i.e. includes power losses in heat station.

2 Mainly limited by the rating of resonant capacitors. Consult manufacturer for operating

at output voltages above 500V rms.

3 When using the adjustable start-frequency feature.

1.4. Front panel controls and indicators

LED Indicators

Yellow indicator for limit.

Red indicators for fault and trip.

Red indicator for fault.

Yellow and Green indicators for heat

on and off.

Numeric Displays Run time read-outs for:

Job and Step for Programmed mode

Elapsed time for heat period

power meter (0-100%)

LCD Display Working mode and Messages for fault,

trip and limit

Run time read-outs for:

Power demand, operating frequency,

capacitor voltage and inverter current

Controls – Switch and knob Push button switch for Heat ON/OFF.

Single turn knob for power level.

(Manual mode)

Pushbutton to reset trips.

Emergency stop button.

Program keys 21 keys for Program and monitoring

command

1.5. Internal heat station

Resonant capacitors Mounting space provided for sixteen

capacitors. Eight 210nF, 500V or 8

200nF, 700V capacitors supplied.

330nf available

Series Parallel Capacitor Rail Kit available (optional)

Series inductor Adjustable for load matching

1.6. Protection

Power Limited to 12.5kW in any feedback

configuration

Inverter output current Limited to 250A peak. Short circuit

protected.

Resonant capacitor voltage Limited to 500V rms

Line current 50A Circuit breaker

DC link current 80A Semiconductor fuse

Temperature and cooling water Temperature switch on inlet water.

Differential pressure switch between

water inlet and outlet.

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.

Connection Selectable between left and right.

Custom output connection provided.

1.8. Cooling water

Maximum pressure 100PSI (690kPa)

Minimum differential pressure 30PSI (207kPa)

Minimum water flow 2GPM (0.126l/s)

Maximum inlet water temperature 110F (43.3C)

Minimum inlet water temperature Approx. 90º F (32ºC)**

Minimum water resistivity 590.in (1500.cm)

Supply hose location Selectable between left or right

** must be set above dew point (see page 29)

2. Getting started

2.1. Safety Warnings

HIGH FREQUECY RADIATION can interfere with radio navagation, safety

services, computers and communication equiptment.

Have only qualified person familiar with electronic equiptment perform this

installation.

The user is responsible for having a qualified electrician promptly correct any

interference problem resulting from the installation.

Any modifications performed on this power supply may void warranty.

Contact manufactor for approval before any modifications are performed.

Have the installation regularly checked and maintained.

Keep high-frequency source door and panels tightly shut.

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 input AC voltage is live at the top of the main circuit

breaker and the control power circuit breaker. The door

interlock will prevent the main breaker from being closed when

the door in opened, but the control power breaker can be on

and 240VAC can be live inside the cabinet.

2.2. Set-up

The following is a list of steps describing the required actions to get the power supply

set up.

1. Check for any visual damage that could have happened during shipment. Check all

plug-in connectors on PCBs.

WARNING: Make sure that the

power is locked out before

connecting the input power.

2. Ensure that both the circuit breakers, located on the door of the unit, are in the OFF

position. Wire the power supply to the supply voltage as described in section 0

3. Connect the heating coil and load to the output of the unit (see section 4.).

4. Connect and test the cooling water supply, as described in section 0

5. Read section 0to become familiar with the front panel controls.

6. Do initial setups of the internal heat station, as described in section 6.1.

7. Do the tuning of the heat station, as described in section 6.2 The power supply will

not operate if the emergency stop button is pressed in or the door is not closed.

8. The unit is now ready for operation, and can be controlled by the front panel.

9. The unit is programmed for power control. For inverter current, load voltage or

auxiliary control see section 5.1.

3. Connections

This section gives a description of the required steps to connect the supply voltage,

load, cooling water and remote loader to the unit. 3

3.1 Three phase input voltage

WARNING: Make sure that the

power is locked out before

connecting AC power to the unit.

Connect only 220-240V, 3~.

A hole needs to be punched in the cabinet of the

power supply for the supply voltage cable. It can

be done in one of two recommended locations.

The primary location (1) is on the left side of

cabinet next to left blank cover. The second

location (2) is at right side rear. Cut-outs in

cabinets will be available and cover plates will

be removable to make it easy for drilling holes

for power cables.

(3) A third cutout is provided for control

wiring.

3.2 Load

The load can be connected to the left or right side of the power supply. The unit is

shipped with the output on the right hand side. To change the output to the left hand

side, exchange the copper output blocks and covers between the two sides. The load or

cables connect to the output blocks. Ensure o-rings are used to avoid water leakage.

See Figure 2.

Figure 2: Output blocks mounting.

3.3 Cooling water

The cooling water can be connected to the left or right side of the power supply. The

unit is shipped with the water inputs on the left hand side. Two female ¼” NPT

connections are provided. If required, move the water fittings to the right hand side.

Keep the input towards the back of the unit and output towards the front of the unit

location. The unit will not operate if the water flow is reversed.

Turn on the cooling water flow and verify that it meets the minimum requirements as

given in section 1.8. on page 5. Check for any water leaks on the inlet, outlet and

heating coil. Tighten connections if necessary. Also check for any water leaks inside the

unit that could have been caused by shipping, and tighten any hose clamps if

necessary.

4. Front panel description and operation

4.1 Front panel description

This section identifies and describes the various parts of the front panel.

1 2

3 5

7 8 9

1) Fault, Trip and Limit LEDs

2) Heat On/Off LEDs

3) Program Indicator

4) Time Indicator

5) Power Indicator

6) LCD display

7) Reset button

8) Heat switch

9) Power Knob

10) Program Buttons

Figure 3: Front panel layout.

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