kFI025GB40K5v1 03PowerCube32 45 64HIPE [PDF]

Zitiervorschau

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64

Inductive Heaters

PowerCube series 900 and 1800 Installation, Use and Maintenance Manual

Document FI 025 GB 40K5

Revision v1.03

Date 05/12/2008

Software version MPWC71xx

Read this manual carefully before installing, operating or carrying out maintenance on the device. Keep the manual in a safe place for future reference, and in perfect condition. This manual must accompany the device described therein in the case of change of ownership, and until the device is broken up 1

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64

SYMBOLS The equipment is marked with this symbol wherever the user should refer to this manual in order to avoid possible damage. The same symbol appears in the manual at points where warnings or particularly important instructions, essential for safe, correct operation of the device, are given. The equipment is marked with this symbol in the areas where there is dangerous voltage. Only trained maintenance personnel should carry out work in these areas. The same symbol appears in the manual at points where warnings essential for safe, are given. LASER LIGHT: This symbol appears in the present booklet at those points where warnings or information relating to devices with laser pointing are given. Such devices may be dangerous. It is therefore essential that the guidelines reported in this booklet be followed. STRONG MAGNETIC FIELDS can affect pacermakers. Wearers of pacemakers, cardiac defibrillators and other life supports, shall not operate in proximity of the inductor or the heating inductors of this device. Wearers should consult their doctor before operating in a different way. This symbol appears in the manual at points where suggestions, additional information or other relevant notes are given.

REVISION TABLE Rev. Date

Reference

Description

1

23/07/2007

Author TP2 - SP

-

First emission

1.01

30/10/2007

TP2 – SP

-

Minor corrections

1.02

05/12/2008

TP2 – SP

Par.2.8

Minor corrections

1.03

14/07/2009

TP2 - SP

Par.6.1

EC Certificates updated

Warranty terms The warranty on all CEIA products, extended to the period agreed with the Sales Department, is applicable to goods supplied from our factory, and for every constituent part thereof, with the exception of the batteries. Any form of tampering with the device, and in particular opening its container, is strictly forbidden and will invalidate the warranty.

Customer Satisfaction Report Your suggestions and comments on the products and services offered by CEIA and its distribution network are extremely important for improving our procedures. We would ask you to send them to us by compiling and returning the form available at:

http://www.ceia-power.com/satisfaction.asp Thank you for your kind interest and co-operation.

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64

CONTENTS SYMBOLS ...............................................................................................................................................................2 REVISION TABLE...................................................................................................................................................2 WARRANTY TERMS................................................................................................................................................2 CONTENTS .............................................................................................................................................................3 1 - SAFETY INSTRUCTIONS - WARNINGS..........................................................................................................5 1.1 - WARNINGS ...................................................................................................................................................5 1.1.1 – General warnigns............................................................................................................................................... 5 1.1.2 – Installation warnings .......................................................................................................................................... 5 1.1.3 – Use warnings ..................................................................................................................................................... 6 1.1.4 – Maintenance warnings ....................................................................................................................................... 7

1.2 – RESIDUAL RISKS ...........................................................................................................................................7 1.2.1 – Use .................................................................................................................................................................... 7 1.2.2 – Maintenance ...................................................................................................................................................... 7

1.3 – CORRECT AND FORBIDDEN USE OF THE DEVICE .............................................................................................8 1.3.1 – Correct use of the device ................................................................................................................................... 8 1.3.2 –Forbidden use of the device................................................................................................................................ 8

2 - DESCRIPTION ...................................................................................................................................................9 2.1 – GENERAL DESCRIPTION ................................................................................................................................9 2.1.1 – Description ......................................................................................................................................................... 9

2.2 – FUNCTIONAL DIAGRAM .................................................................................................................................9 2.3 - COMPONENTS .............................................................................................................................................10 2.3.1 – PowerCube 32/45 ............................................................................................................................................ 10 2.3.2 - PowerCube 64 .................................................................................................................................................. 10 2.3.3 – Heating Head ................................................................................................................................................... 11 2.3.4 - Available adductors .......................................................................................................................................... 12 2.3.5 - Adjustable supports for heating heads.............................................................................................................. 12 2.3.6 - Activation pedal ................................................................................................................................................ 14

2.4 - SAFETY DEVICES AND WARNING LABELS .......................................................................................................14 2.5 – OPTIONS....................................................................................................................................................14 2.6 - ACCESSORIES.............................................................................................................................................15 2.6.1 – Heating head HH10 ......................................................................................................................................... 16 2.6.2 – Heating head HH11 ......................................................................................................................................... 16 2.6.3 – Heating head HH15 ......................................................................................................................................... 16

2.7 – SPARE PARTS ............................................................................................................................................17 2.7.1 – PowerCube 32/900 .......................................................................................................................................... 17 2.7.2 – PowerCube 45/900 .......................................................................................................................................... 17 2.7.3 – PowerCube 64/900 .......................................................................................................................................... 17 2.7.4 – PowerCube 32/1800 ........................................................................................................................................ 17

2.8 – TECHNICAL CHARACTERISTICS ....................................................................................................................18 2.8.1 – Common features ............................................................................................................................................ 18 2.7.2 – Different features ............................................................................................................................................. 18 2.8.3 – Heating heads.................................................................................................................................................. 19

3

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64

3 - INSTALLATION ...............................................................................................................................................20 3.1 – MECHANICAL INSTALLATION ........................................................................................................................20 3.1.1 – Minimum requirements .................................................................................................................................... 20 3.1.2 – Assembly ......................................................................................................................................................... 20 3.1.3 – Transportation ................................................................................................................................................. 20 3.1.4 – Heating head fastening.................................................................................................................................... 20 3.2.5 – Cooling system ................................................................................................................................................ 21

3.3 - ELECTRICAL INSTALLATION ..........................................................................................................................23 3.3.1 – Minimum requirements .................................................................................................................................... 23 3.3.2 – Selection and installation of the connecting cables ......................................................................................... 23 3.3.3 – Connection of the heating heads ..................................................................................................................... 23 3.3.4 – Connection of the activation pedals ................................................................................................................. 24 3.3.5 – Connections for the analogic adjustment of the output power (optional) ......................................................... 24 3.3.6 – Connection to the power supply ...................................................................................................................... 25 3.3.7 – Serial connection (PowerCube 64) .................................................................................................................. 25 3.3.8 – Connection to other devices of the PowerCube Family ................................................................................... 26 3.3.9 – Connection to an external signalling relais ...................................................................................................... 26

4 - USE OF THE DEVICE......................................................................................................................................27 4.1 - INDICATORS ................................................................................................................................................27 4.1.1 – Optical indicators ............................................................................................................................................. 27 4.1.2 – Display messages ........................................................................................................................................... 27 4.1.3 – Acoustical indicators ........................................................................................................................................ 28

4.2 – CONTROLS .................................................................................................................................................28 4.3 – USE OF THE DEVICE ....................................................................................................................................28 4.3 - PROGRAMMING ...........................................................................................................................................29 4.3.1 - Selection of the head and regulation of the heating power............................................................................... 29

5 - MAINTENANCE ...............................................................................................................................................30 5.1 – PERIODICAL MAINTENANCE .........................................................................................................................30 5.2 - REPLACEMENT OF THE SUPPORT-HEATING INDUCTOR GROUP ........................................................................30 5.2.1 – Heating inductor soldering ............................................................................................................................... 30 5.2.2 - Support-heating inductor group replacement procedure .................................................................................. 31

5.3 - TROUBLESHOOTING.....................................................................................................................................31 6 - APPENDICES ..................................................................................................................................................33 6.1 – DECLARATIONS OF CONFORMITY CE...........................................................................................................33 6.1.1 – PowerCube 32/900 .......................................................................................................................................... 33 6.1.2 – PowerCube 32/1800 ........................................................................................................................................ 34 6.1.3 – PowerCube 45/900 .......................................................................................................................................... 35 6.1.4 – PowerCube 64/900 .......................................................................................................................................... 36

6.2 - SHAPE AND POSITION OF THE INDUCTOR .......................................................................................................37 6.2.1 - Flow of Cooling Water ...................................................................................................................................... 37 6.2.2 - Dimensions of the heating inductor .................................................................................................................. 38 6.2.3 - Dimensions of the heating inductor .................................................................................................................. 39 6.2.4 - Optimisation of the generator efficiency with small dimension inductors .......................................................... 39

6.3 - CONSTRUCTION OF EQUIPMENT, CLAMPS, AND MATRIXES ..............................................................................40 6.3.1 - Materials to use ................................................................................................................................................ 40 6.3.2 - Dimensions of the parts.................................................................................................................................... 40

6.4 - USE OF ANTI-OXIDIZING GAS ........................................................................................................................41 6.5 – CONTROL VIA RS232 SERIAL INTERFACE .....................................................................................................41 6.5.1. Setting of the Terminal....................................................................................................................................... 41 6.5.2. Starting of the connection .................................................................................................................................. 41 6.5.3. Commands ........................................................................................................................................................ 42

4

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 SAFETY INSTRUCTIONS - WARNINGS

1

Read this manual carefully before installing, operating or carrying out maintenance on the device.

1 - SAFETY INSTRUCTIONS - WARNINGS 1.1 - Warnings 1.1.1 – General warnigns -

-

-

-

Soldering processes which have been developed over the years may be employed with a high degree of safety provided that all the safety regulations suggested by common sense and by the manufacturer's recommendations are observed. It is therefore essential that heads of staff safety make sure that all operators read this manual before being allowed to use the device. Follow the instructions contained in this manual for all operations relating to installation, use and maintenance of the device. CEIA cannot be held responsible for any damage resulting from procedures which are not expressly indicated in this manual, or from any lack of attention, either partial or total, of the procedures described therein. Whenever there is any suggestion that the level of protection has been reduced, the device should be taken out of service and secured against any possibility of unintentional use, and authorised service technicians should be called. The level of protection is considered to have been reduced when: - the device shows visible signs of wear and tear, especially on parts that ensures the device protections (boxes, gaskets, glands, fixing screws, etc.); - the electrical cables or the equipotential ground connections are damaged. - the ground connections are not compliant; - the device has suffered mechanical or electrical stress (shocks, bumps, etc..); - the device does not operate correctly, respect on how described in this manual; - the device has been stored for long periods in sub-optimal conditions; - the device has suffered severe stress during transport; - the inside of the device has come into contact with liquids. - the device was present inside an environment where a fire or an explosion took place. This equipment complies with European (CE) and International Standards on Electrical Safety and Electromagnetic Compatibility. However, CEIA will not accept any liability for damage to objects or people due to improper use or to specific incompatibility with equipment of a different nature.

1.1.2 – Installation warnings The device is designed to be inserted as a component part of a heating system; the safety devices needed to protect the operators must therefore be designed and fitted by the installer according to the type of application in question. -

-

Ensure that there is adequate fire-fighting equipment sufficiently close to the working area. Choose the installation site carefully. Avoid placing the device in locations where it may be directly exposed to sunlight or in places that are close to sources of heat. In addition, avoid places that are subject to vibrations, dust, humidity, rain and excessively high or low temperatures. Handle the device with care and without excessive force during installation, use and maintenance. The operator must be able to access the controls of the device easily, without running personal risks. To avoid damage due to lightning, fit the power supply line with appropriate surge suppressors. This device contains electrical and electronic components, and may therefore be susceptible to fire. Do not install in explosive atmosphere or in contact with inflammable material, 5

1

FI 023 I 2K8 v2 – Manuale Istruzioni THS/G-ATEX SAFETY INSTRUCTIONS - WARNINGS -

-

-

-

After installation the device should be stable, and not subject to vibration or accidental movement. All connecting cables should be properly fastened down, in order to avoid knocks and accidental damage and to obtain optimum performance. If the device is to be powered via an external autotransformer to regulate the voltage, ensure that the common terminal of the autotransformer is connected to the neutral of the powersupply circuit. The electrical plug must only be inserted into a socket containing a grounding contact. Any interruption in the protective conductor either inside or outside the device, or the detaching of the protective grounding terminal, renders the device dangerous. Intentional interruption is forbidden. Before providing the device with electrical power, check that the voltage from the power mains corresponds to the voltage shown on the device's electrical specifications plaque. Only connect the device to the power mains after having made all the connections needed for its complete installation.

1.1.3 – Use warnings STRONG MAGNETIC FIELDS can affect pacermakers. Wearers of pacemakers, cardiac defibrillators and other life supports, shall not operate in proximity of the inductor or the heating inductors of this device. Wearers should consult their doctor before operating in a different way. -

-

-

-

Never carry out soldering operations on metal pieces that have been in contact with toxic combustible products; such pieces must be carefully cleaned before undergoing any soldering operations. Maximum care must be taken to avoid incandescent metals coming into contact with combustible materials. Ensure that there is adequate fire-fighting equipment sufficiently close to the working area. All combustible materials must be removed from the working area and placed at a safe distance. During the generating phase do not allow limbs or other parts of the body bearing metal to come near the heating coil. The minimum safety distances of 50cm must be maintained during generator activation. During normal use, the heater does not produce sparks. Electrical discharges may however occur during soldering, near the heating inductor, in the event of accidental contact between the inductor and metal parts with a ground connection. ATTENTION! This device may be equipped with an optical pyrometer with laser pointing. Use of the device for operations or functions not expressly indicated in this booklet may cause exposure to dangerous radiation.

LASER LIGHT DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH OPTICAL INSTRUMENTS CLASS 3A LASER PRODUCT (EN 60825-1:1994)

-

-

6

After soldering, ensure that the piece that has been worked upon is allowed sufficient time to cool before handling it or bringing it into contact with combustible material. All electrical shocks are potentially fatal. Never touch parts charged with mains power. Keep clothes and body dry and never work in wet environments. If you ever have cause to believe that the device or part of it has accidentally become electrically charged, stop soldering operations immediately and do not use the device until the problem has been located and resolved by qualified personnel. Always remove the plug by hand when disconnecting the power supply cable, never by pulling on the cable. This device contains electrical and electronic components. Do not use water or foam in the case of fire when the device is powered up.

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 SAFETY INSTRUCTIONS - WARNINGS

1

1.1.4 – Maintenance warnings -

-

Do not wash the device with liquid detergents or chemical substances. Any cleaning should be done using a slightly-damp, non-abrasive cloth. Before any maintenance, cleaning or movement, the device must first be disconnected from all sources of power. Read the chapter on "Maintenance" carefully before calling the service centre. Whatever the problem, only specialised service personnel authorised to work with CEIA equipment should be called. Any damaged parts of the device should be replaced with original components only. Any maintenance or repair of the device while open and energised should be avoided, and in any case should only be carried out by trained personnel who are fully aware of the risks which the operation entails, following the instructions given in the Maintenance section.

1.2 – Residual risks 1.2.1 – Use -

In particular, direct or indirect contact with the heating inductor must be prevented, and the following minimum safety distances must be maintained during generator activation: 5 cm for metal objects and parts of the body. At distances less than the above safety limits, heating of metal objects may occur even without direct contact, with a consequent risk of burns for the operator.

STRONG MAGNETIC FIELDS can affect pacermakers. Wearers of pacemakers, cardiac defibrillators and other life supports, shall not operate in proximity of the inductor or the heating inductors of this device. Wearers should consult their doctor before operating in a different way. -

During activation of the generator the heating inductor is powered at a dangerous voltage (as per regulation CEI EN 61010-1, par. 6.3.1): avoid direct contact and indirect contact via metal objects.

1.2.2 – Maintenance -

The capacitors within the device may remain charged even after the device has been disconnected from all sources of power. Wait 60 seconds before beginning repair work on the device.

7

1

FI 023 I 2K8 v2 – Manuale Istruzioni THS/G-ATEX SAFETY INSTRUCTIONS - WARNINGS

1.3 – Correct and Forbidden use of the device 1.3.1 – Correct use of the device The device is designed to be inserted as a component part of a heating system; the safety devices needed to protect the operators must therefore be designed and fitted by the installer according to the type of application in question. -

The PowerCube 32/45/64 generators are induction heaters dedicated to the soldering, without contact, of metal components. Any other use shall be avoided.

1.3.2 –Forbidden use of the device -

8

During the generating phase do not allow limbs or other parts of the body bearing metal to come near the heating coil. The minimum safety distances of 50cm must be maintained. The heating phase shall not be started, for any reason, in presence or in the nearby of tanks under pression, explosive or inflammable atmosphere or liquids. Any different use, from the specifications of paragraph 1.3.1 - Correct use of the device, is forbidden.

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

2 - DESCRIPTION 2.1 – General description 2.1.1 – Description The basic configuration of the Inductive Heater PowerCube is as follows: - a programmable generator, controlled by microcomputer; - two miniaturized heating heads with adjustable supports; - two on/off pedals to activate the working cycle. The device is also designed to be connected to other devices from PowerCube Family. The system can be fitted with a pyrometer in order to control the temperature of the piece being worked upon (option) and an Anti-oxidizing gas diffusion system placed near the heating area.

2.2 – Functional Diagram An inductor with a suitable shape (IND) connected to the head emits an electromagnetic field. Metals located within the inductor heat up due to the currents induced by this magnetic field: The shape of the inductor depends on the type of application; CEIA does not physically supply the head, which must be produced by the heating system constructor.

Block diagram of a PowerCube 32 soldering station. M: metal object to be heated; IND: heating inductor

9

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2.3 - Components 2.3.1 – PowerCube 32/45 The generator of the models PowerCube 32 and PowerCube 45 is made up of a central electronics unit which includes a power supply stage, a generator of high frequency and a control section . The management of the apparatus is entrusted to a microcomputer that monitors the correct functioning of the machine by means of a self-diagnosis device and signals, by display, any necessary interventions on the part of the operator.

1

Alphanumeric display which shows the functioning messages

2

Two push-button for the regulation of the power delivered by the heads Indications about the self-diagnosis messages (see Maintenance chapter) and the functioning of the equipment

3 4

Magnetothermal on/off switch

5

Power supply cable

6

The connectors and terminals necessary for the installation of the device

7

Label with the indications of the power supply, the model of the equipment and the serial number

2.3.2 - PowerCube 64 The generator of the PowerCube 64 is made up of two central electronics units: -

a unit for the management and the programming MAIN UNIT a supporting unit SLAVE UNIT.

the two central electronics units include a power supply stage, a generator of high frequency and a control section. The management of the apparatus is entrusted to a microcomputer that monitors the correct functioning of the machine by means of a self-diagnosis device and signals, by display, any necessary interventions on the part of the operator.

10

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

2.3.3 – Heating Head The PowerCube generator allows connection to different heating heads, one for each soldering point: - HH10 model for PowerCube 32/900 and 45/900; - HH10 model for PowerCube 32/1800 (only on Spectacle Frame Line) - HH11 model for PowerCube 64/900. - HH15 miniaturised model (only for PowerCube 32/900, 32/1800 and 45/900). The container of the head  is constructed of plastic with a high thermal and mechanical resistance. From the front a metal connection (conductors ), comes out upon which the inductor  that generates the electromagnetic field is soldered. Above the connection there is a luminous indicator , which signals the operation of the head. On the back there is the exit of the connecting cable to the generator  and two connections for the head cooling water .

Heating head HH10 (* refers to model 32/1800)

Heating head HH15

11

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2.3.4 - Available adductors In addition to the standard adductor, suitable for general use, a shortened adductor with largerdiameter tubes (3mm instead of 2mm) is also available. This special adductor is designed for continuous use at high power: the greater flow of water prevents overheating of the inductor. 29

29 ø2

ø2

ø3

29 50

50

82.5

82.5

150

50

100

Standard adductor (tube ø2mm)

65

Standard adductor for model 32/1800 Short adductor, specifically for (tube ø2mm) inductors with a high cooling flow-rate (tube ø3mm)

2.3.5 - Adjustable supports for heating heads The head can be furnished with an adjustable support for the positioning of the inductor in the work area. Standard adjustable support ES25 The support allows a micrometric movement of the head along the horizontal axes, a weighted movement vertically (the movement measurements are shown in the illustration), and a rotation of 360°. 150

123

42 ± 142

~80

95

62,5

60

60

M5 20mm

20mm

20mm 20mm

Adjustable support ES25

12

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

Adjustable precision support for heating head ES35L/R Two different positioning supports are available: ES35L (left point) and ES35R (right point); the supports are constructed specularly to allow easy positioning on symmetrical workstations. The support allow a micrometric movement of the head along the horizontal axes, a weighted movement vertically (the movement measurements are shown in the illustration), and a rotation of 360°

60

ø5,5

80

24 1 M5

13,5

360˚

±11

2

159

3 ±11

±11

1

78

1

100

80

146

136

adjustable precision support ES35L

13

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2.3.6 - Activation pedal The PowerCube can be connected to two pedals for the activation of each of the soldering heads. In the case of remote command, the pedal can be substituted by a button which is normally open.

2.4 - Safety devices and warning labels IP Protection degree Selfdiagnosis system

The device has a protection degree IP20 Built-in. See paragraph 5.3 of this manual

2.5 – Options Options

Part Number PowerCube 32/900 Industrial Line

PowerCube 32/900 Spectacle Frames Line

PowerCube 32/1800 Spectacle Frames Line

PowerCube 45/900 Industrial Line

PowerCube 45/900 Spectacle Frames Line

PowerCube 64/900 Industrial Line

PowerCube 64/900 Spectacle Frames Line

14

Standard

PW3-32/900-IND

With analogic adjustment of the power output

PW3-32/900-IND-AC

Standard

PW3-32/900-FRM

With analogic adjustment of the power output

PW3-32/900-FRM-AC

Standard

PW3-32/1800-FRM

With analogic adjustment of the power output

PW3-32/1800-FRM-AC

Standard

PW3-45/900-IND

With analogic adjustment of the power output

PW3-45/900-IND-AC

Standard

PW3-45/900-FRM

With analogic adjustment of the power output

PW3-45/900-FRM-AC

Standard

PW3-64/900-IND

With analogic adjustment of the power output

PW3-64/900-IND-AC

Standard

PW3-64/900-FRM

With analogic adjustment of the power output

PW3-64/900-FRM-AC

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

2.6 - Accessories Accessory

Part Number

Activation pedal

3457

1000x700x1370 working desk with raised shelf for generators and controllers

25908

-

Standard adductors kit - 150mm (1 adductor, 6 o-ring, 4 screws and a tool)

32836

-

1800 series adductors kit - 100mm (1 adductor, 6 o-ring, 4 screws and a tool)

32837

-

Short adductors kit - 70mm (1 adductor, 6 o-ring, 4 screws and a tool)

32838

-

Assembled standard adductor - 150mm

3459

-

Assembled 1800 series adductor - 100mm

14123

-

Assembled short adductor - 70mm

3461

ES25 heating head support

3454

ES35 precision heating head support

9252

ES35/P precision heating head support with pneumatic movements

30313

ES35/PS precision heating head support with pneumatic movements and positioning sensors

31166

Ceramic cylinder - ø5 L100mm

29101

Ceramic cylinder - ø3 L100mm

16633

-

ø5 spare o-rings kit (25 pieces)

32839

-

Adductors spare screws kit (8 pieces)

32841

-

Coil kit (1m of tube, 1m of tin)

32842

-

3mm coil kit (2m of tube, and sheath) Only for HH10 and HH11

32843

-

Copper tube Only for HH10 and HH11

35514

-

Sheath in insulating vetrotex

20096

-

15

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2.6.1 – Heating head HH10 Accessory

Spare part Full HH10 heating head 1.5 m cable length

PWH-10-XX-15/900

3.0 m cable length

PWH-10-XX-30/900

4.0 m cable length

PWH-10-XX-40/900

Custom cable length

PWH-10-XX-CC/900

2.6.2 – Heating head HH11 Accessory

Spare part Full HH11 heating head 1.5 m cable length

PWH-11-XX-15/900

3.0 m cable length

PWH-11-XX-30/900

4.0 m cable length

PWH-11-XX-40/900

Custom cable length

PWH-11-XX-CC/900

2.6.3 – Heating head HH15 Accessory

Spare part Full HH15 heating head

16

1.5 m cable length

PWH-15-XX-15/900

3.0 m cable length

PWH-15-XX-30/900

4.0 m cable length

PWH-15-XX-40/900

Custom cable length

PWH-15-XX-CC/900

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

2.7 – Spare parts Spare part -

Part number ALM Power supply card

43588

2.7.1 – PowerCube 32/900 Spare part

Part number

-

SCD Control card

43589

-

PTS Card

43586

-

PTZ Mosfet card

43590

2.7.2 – PowerCube 45/900 Spare part

Part number

-

SCD Control card

43589

-

PTS Card

43587

-

PTZ Mosfet card

43590

2.7.3 – PowerCube 64/900 Spare part

Part number

-

SCD Control card – Main unit

43591

-

SCD Control card – Slave unit

43592

-

PTS Card

43593

-

PTZ Mosfet card

43590

2.7.4 – PowerCube 32/1800 Spare part

Part number

-

SCD Control card

43595

-

PTS Card

43598

-

PTZ Mosfet card

43597

17

2

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2.8 – Technical characteristics 2.8.1 – Common features Power and supplies Cooling

Operational mode

Command mode Management and controls Self-diagnosis

Generator

Safety features

Operating conditions

Power supply Water cooling system

180-260V~, monophase - 50/60 Hz Water cooling, by means of tank of 200dm3 with 0.4 Hp pump or with direct pressure of about 300kPa (minimum pressure of 150kPa, maximum pressure of 600kPa): Input water temperature From environmental temperature to a maximum of 45°C (without condense) Spectacle Frame Line Intermittent activation of one head Intermittent activation and alternated over two heads Industrial Line Continued activation of one head Alternated activation over two heads Manual or Automatic (controlled by a device of the PowerCube Family) Cycle activation by means of pedal or external control Analogic regulation of the heating power through 0 ÷ 10 V input (optional) Heating power automatically stabilised (not influenced by variations in the power supply) Digital regulation of the heating power: 10 - 99 % Any malfunctioning is Monitors of the temperature and Monitors of that the coil size is correct indicated by a display pressure of the cooling water signal and a buzzer Monitors of possible short-circuit of Monitors of head connection the heating coil Monitors of the power supply voltage Internal malfunctioning value Monitors of the correct connection between the Main Unit and the Slave Unit (PowerCube 64) Type Container in stainless steel Dimensions (W x D x H) 275 x 265 x 140 mm / 10.8x10.4x5.5 in (the PowerCube 64 comprises two control units of the same dimensions) Power supply cable 2,6 m Hydraulic connection to 1/8" connections by 6/4 mm rubber tube (PowerCube 32 and 45) and from the cooling unit 1/8" connections by 8/6 mm rubber tube (PowerCube 64) Hydraulic connection to 1/8" connections by 6/4 mm rubber tube and from the heating heads Power supply feed galvanically insulated Low operational voltage: no danger to the operator Conform to the international standards currently applicable for electrical safety, E.M.C. and to the applicable CE regulations Working temperature +15 / +55 °C Storage temperature -20 / +70 °C Relative humidity 0 – 95% (without condense)

2.7.2 – Different features

Generator

Cooling

18

Input current Average power at inductor Weight Water flow for each connected head

PowerCube 32/900 & 32/1800

PowerCube 45/900

PowerCube 64/900

13A max Ext. conduct. ø2.5 min. 32 kVAR 10 kg

16A max Ext. conduct ø4 min. 45 kVAR 10 kg

2 lines for 13A max Ext. conduct ø2.5 min. 64 kVAR 20 kg

from 1.5 to 2 l/min

from 1.5 to 2 l/min

from 4 to 5 l/min

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 DESCRIPTION

2

2.8.3 – Heating heads Common characteristics

PWH-10-XX-XX/900 PWH-11-XX-XX/900 PWH-15-XX-XX/900

Weight Cable for the connection with generator Inductors shape corresponding to the piece being worked upon Hydraulic connection to and for electronics unit Model Dimensions (WxDxH) without adductor Model Dimensions (WxDxH) without adductor Model Dimensions (WxDxH) without adductor

2 kg Length 1.5 m – 10 pins connector In their construction the use of a silver-plated copper tube is advised (external diameter of 1.8 mm) 1/8" connections by 6/4 mm rubber tube, length 1.5m PowerCube 32 & 45 62.5x123x95 mm / 2.5x4.8x3.7 in PowerCube 64 62.5x123x95 mm / 2.5x4.8x3.7 in PowerCube 32 & 45 52x107x77 mm / 2x4.2x 3 in

19

3

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3 - INSTALLATION Before starting any installation operation, read carefully the Safety instructions - Warnings section of this manual.

3.1 – Mechanical installation 3.1.1 – Minimum requirements Position and fasten the soldering workstation components according to the processing required in order to allow installation, bearing in mind: - the length of the connecting cables; - the electrical and hydraulic requirements; - the modes of fastening. Arrange the two workstations, installing the parts in such a way as to facilitate processing. 3.1.2 – Assembly The PowerCube 32/45/64 is supplied already assembled. 3.1.3 – Transportation Hold tightly the generator through its handlings. 3.1.4 – Heating head fastening The heating head must be fastened to the working desk or to an adequate positioning support. See the drawings below for the fixing holes and distances.

HH10 Heating head

HH15 Heating head

20

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3

3.2.5 – Cooling system For the cooling system characteristics see paragraph Technical characteristics. PowerCube 32 and 45 - Connect the output of the external cooling unit to the "H20 IN" terminal of the central electronics unit; insert a security tap up-flow. ATTENTION! The cooling water, entering the generator, shall go from environmental temperature up to a maximum of 45°C, without condensation. -

Connect the input of the external cooling unit to the "H20 OUT" terminal of the central electronics unit.

WARNING! Do not invert load and drain: in this case, the generator will not start.

-

-

Connect the water connections of Head 1 to the "H2O IN 1" and "H2O OUT 1" terminals of the central electronics unit. Connect the water connections of Head 2 to the "H2O IN 2" and "H2O OUT 2" terminals of the central electronics unit.

COOLING SYSTEM

In case of installation of the generator with only one head, it is necessary to insert the special cap (PS24) in the "H2O OUT 2" and "H2O IN 2" terminals.

COOLING SYSTEM

IMPORTANT! - Flow of Cooling Water For correct operation the flow must not be less than the minimum for each model as stated in the “Technical Characteristics” section of the manual. The use of inductors constructed with tubes of reduced diameter or of a shape which creates constriction (severely reduced dimensions or sharp bends) may cause a decrease in the flow sufficient to result in inductor overheating. If process requirements necessitate the use of this type of inductor, the water input pressure must be increased, remaining within the limits stated in the “Technical Characteristics” section.

21

3

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION PowerCube 64 - Connect the output of the external cooling unit to the "H2O IN" terminal of the SLAVE UNIT; insert a security tap up-flow. - Connect the "H2O OUT" terminal of the SLAVE UNIT to the "H2O IN" terminal of the MAIN UNIT - Connect the input of the external cooling unit to the " H2O OUT" terminal of the MAIN UNIT. WARNING! Do not invert load and drain: in this case, the generator will not start.

-

-

Connect the water connections of Head 1 to the "H2O IN 1" and "H2O OUT 1" terminals of the MAIN UNIT. Connect the water connections of Head 2 to the "H2O IN 2" and "H2O OUT 2" terminals of the MAIN UNIT.

COOLING SYSTEM

In case of installation of the generator with only one head, it is necessary to insert the special cap (PS24) in the "H2O OUT 2" and "H2O IN 2" terminals of the MAIN UNIT

COOLING SYSTEM

IMPORTANT! - Flow of Cooling Water For correct operation the flow must not be less than the minimum for each model as stated in the “Technical Characteristics” section of the manual. The use of inductors constructed with tubes of reduced diameter or of a shape which creates constriction (severely reduced dimensions or sharp bends) may cause a decrease in the flow sufficient to result in inductor overheating. If process requirements necessitate the use of this type of inductor, the water input pressure must be increased, remaining within the limits stated in the “Technical Characteristics” section. 22

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3

3.3 - Electrical installation 3.3.1 – Minimum requirements See the values indicated on paragraph 2.7 – Technical characteristics. 3.3.2 – Selection and installation of the connecting cables All cables needed to use PowerCube 32, 45 and 64 are supplied. Do not use different cables. 3.3.3 – Connection of the heating heads PowerCube 32 and 45 Connect the cable of the Head 1 into the socket "HEAD 1" and the cable of the Head 2 into the socket "HEAD 2" of the central unit; tighten well the metal ring of the connector.

PowerCube 64 Connect the cables of the Head 1 into the sockets "HEAD 1" and the cables of the Head 2 into the sockets "HEAD 2" of the two control units; the two cables of each head are interchangeables. Tighten well the metal ring of the connectors.

23

3

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3.3.4 – Connection of the activation pedals PowerCube 32 and 45 Connect the PE10 activation pedals to pins 6 and 7 of the connector "ACTIVATION HEADS", to activate the station 1 and to pins 8 and 9 to activate the station 2. PowerCube 64 Connect the activation pedals indicated above, on the MAIN UNIT.

as

Delay in Power activation: the delay, in power activation, after pressing the pedal, is: -

step up (t1): 2 … 3 ms step down (t2): 2 … 3 ms

Pedal switch

Output power t1

t2

3.3.5 – Connections for the analogic adjustment of the output power (optional) PowerCube 32 and 45 The connection with the external control unit, for the analogic adjustment of the output power, is performed through the pins 3 and 4 of connector “ACTIVATION HEADS”, for the station 1, and the pins 3 and 5 for the station 2.

PowerCube 64 Connect the analogic adjustment as indicated above, on the MAIN UNIT. Power adjustment Power / voltage ratio: The power output isproportional to the input control voltage, in the range 10%…99%. When the control input is lower than 1V, the generator is deactivated.

P 99%

50%

10% 0

Delay in Power adjustment: The control voltage is sampled approximatively each millisecond. The delay, in power adjustment, after a variation of the control voltage, is: - step up (t1): 1 … 2 ms - step down (t2): 2 … 3 ms

24

1

5

10

V 10V

Control Voltage

0V 90%

Output Power t1

t2

10%

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3

Enabling the remote control of the output power The option with the remote control of the output power can be enabled independently for each one of the heating heads. The option is activated setting the power parameter on value "RE". This value can be set by pressing the down arrow when the lower limit is reached (10%) or the up arrow when the upper limit is reached (99%). 3.3.6 – Connection to the power supply Connect the apparatus to the mains only after all the connections needed for the complete installation have been carried out. Using the power supply cable, connect the machine to the earth and to the frequency specified on the electrical-specifications plaque.

PowerCube 32 and 45

PowerCube 64

The external line shall have conductors with an section adequate to the absorbed current (see “Technical Characteristics”). 3.3.7 – Serial connection (PowerCube 64) Connect the serial cable to the SUB-D 25 poles female connectors (signed with the symbol shown beside) of the two electronics units.

The cables is marked, near the connectors, the control unit to which that side shall be connected (MAIN or SLAVE UNIT): respect this indication.

25

3

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 INSTALLATION

3.3.8 – Connection to other devices of the PowerCube Family PowerCube 32 and 45 For connection to other devices of the PowerCube Family, as Power Controller or Master Controller, use connector "AUXILIARY OUTPUT", type sub-D 9-pole female.

PowerCube 64 For connection to other devices of the PowerCube Family, as Power Controller or Master Controller, use connector "AUXILIARY OUTPUT", type sub-D 9-pole female, of the MAIN UNIT.

With the exception of contact 9, which has a voltage of 24Vcc, the connections are analogous to a normal RS232 interface. 3.3.9 – Connection to an external signalling relais PowerCube 32 and 45 The connection with an external signalling relais is performed through pins 1 and 2 of the connector “ACTIVATION HEADS”. OUTPUT

24VDC / 24VAC - 0,5 AMAX

PowerCube 64 Connect the external relais as indicated above, on the MAIN UNIT.

This output can be set to signal the presence of an alarm (default) or to signal when the generator is ON. See parameter _RO in Serial Programming, at paragraph 6.5.3.

26

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 USE OF THE DEVICE

4

4 - USE OF THE DEVICE Follow the instructions contained in this manual for all operations relating to the use of the device. CEIA cannot be held responsible for any damage resulting from procedures which are not expressly indicated in this manual, or from any failure, either partial or total, to put the procedures described into practice.

4.1 - Indicators 4.1.1 – Optical indicators

a

Control unit display

b

Heating head LED

4.1.2 – Display messages Machine in stand-by When working normally, with the generator in stand-by, the PowerCube display shows which head of the two has been selected and which was the power programmed for the head

H1

99

H1

Head 1 selected, delivered power = 99%.

Soldering activation During soldering, the display shows the power supplied by the inductor, step by step; when the pedal is pressed, power increases very fast up to reaching the programmed power.

46

88

99

Preset power = 99%.

Self-diagnosis messages In case of failure, the display shows a message referred to the problem; for decoding this message and solving the problem, please see chapter "Maintenance" of the present booklet.

A1 Self-diagnosis message A1: water temperature too high

Slave Unit PowerCube 64 Machine in normal functioning. When working normally, with the generator in stand-by, or during a soldering cycle, the Slave Unit display shows an "on" signal

on SLAVE UNIT: normal functioning

27

4

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 USE OF THE DEVICE

4.1.3 – Acoustical indicators The Self-Diagnosis system of each PowerCube warns the operator, in case of fault, through a series of self-diagnosis messagges visualized by the controller display and through an acoustical sound.

4.2 – Controls The PowerCube induction heaters are designed to function in different ways depending on whether or not they are connected to external control devices: 1. Apparatus not connected to any external control: the selected head is activated and continues the heating of the piece being processed for the entire time that the activation pedal is pressed. In this case, the operator controls all the soldering phases. 2. Apparatus controlled by one of the controllers of the PowerCube Family : the PowerCube can be the generating part of a soldering workstation controlled by a device of the "PowerCube Family". The device can be a Power Controller or a Master Controller. These apparatuses control all the required devices in a soldering cycle, such as for example diffusers of anti-oxidizing gas, temperature sensors and soldered-wire feeders (only with Master Controller). The PowerCube itself is also completely controlled by these devices. For information about the apparatuses of PowerCube Family contact our sales department or the nearest distributor.

4.3 – Use of the device The list of operations that follows assumes that the inductor, any equipment for positioning the piece to be processed and any accessory devices have already been manufactured and properly positioned during the welding system installation phase, so that the operator can carry out the work cycle correctly and safely. Before operating the equipment, all safety measures designed to prevent parts of the body or objects approaching the heating inductor during activation of the generator must be put in place. 1. Turn on the necessary power and water supplies, then activate the on/off switch located on the rear panel of the generator. 2. Position the heating head so as to facilitate the desired process (see next pages). At the beginning of every working shift, check the efficiency and physical integrity of the safety devices designed to prevent the operator approaching the inductor during heating. 3. Adjust the power delivered by heads 1 and 2 4. Position the pieces to be soldered close to the heating coil, making sure that they do not touch the coil (see next pages).

28

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 USE OF THE DEVICE

4

In particular, direct or indirect contact with the heating inductor must be prevented and the minimum safety distance of 5cm must be maintained during generator activation. At distances less than the above safety limits, heating of metal objects may occur even without direct contact, with a consequent risk of burns for the operator. During activation of the generator the heating inductor is powered at a dangerous voltage (as per regulation CEI EN 61010-1, par. 6.3.1): avoid direct contact and indirect contact via metal objects. STRONG MAGNETIC FIELDS can affect pacermakers. Wearers of pacemakers, cardiac defibrillators and other life supports, shall not operate in proximity of the inductor or the heating inductors of this device. Wearers should consult their doctor before operating in a different way. 5. Soldering cycle: manual mode: press the activating pedal, bring the piece to the desired temperature, solder, and deactivate the heating. automatic mode (heater connected up to external control devices): activate the cycle, and carry out the required operations. 6. When work is finished unplug the power supply and turn off the tap which supplies water.

4.3 - Programming 4.3.1 - Selection of the head and regulation of the heating power In case of a device not connected to any external controller, follow the next procedure to change the value of the machine's delivered power to the inductor: Select the wished head pressing, for a moment, the corresponding pedal (the display will show the indication of the selected head: H1 = Head 1 ; H2 = Head 2);

H1

Increase or decrease the power value supplied with the two arrow keys:

H1

99

H1

Head 1 selected, delivered power = 99%.

99

86

Modification of programmed power From value 99% to value 86%.

29

5

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 MAINTENANCE

5 - MAINTENANCE Before performing any maintenance operation on the device, read carefully the Safety instructions - Warnings section of this manual.

5.1 – Periodical maintenance In the following table the maintenance periodical operations are indicated suggested frequency: Intervention

Frequency

Operator

Head contacts drying

At each inductor change

Operator

together with their

Procedure Dry accurately the contact surfaces of the inductor before mounting it back, to avoid the joint burning.

The operator shall evaluate the system status and its working capability, according eventually with the maintenance personnel.

5.2 - Replacement of the support-heating inductor group If it is necessary to use different inductors for different work processes, we suggest preparing individual support-inductor groups. 5.2.1 – Heating inductor soldering The inductor is attached to the heating head support by means of tin soldering. During the operation , be careful that: The insulating diaphragm located between the two metal parts should be complete and should not show signs of burning. If this is not the case, replace it. the conductors of the heads are dry (to this end use a jet of compressed air) the tube enters the heating head ducts by at least 8-10 mm; no traces of tin enter into the conductors of the head (to assure this it is best to operate with the support tilted downwards at a 40° angle, approximately).

30

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 MAINTENANCE

5

5.2.2 - Support-heating inductor group replacement procedure a. Shut off the flow of cooling water to the generator. b. Disconnect the inductor support 2 to be replaced by removing the four bolts 4. (N.B.: if the generator is located above the heating head, water may come out of the head: block the head cooling tubes using clamps, but avoid damage to them). c. Eliminate the water that has come out, drying the front part of the head 1 well with a cloth and a jet of compressed air. d. Remove any remains of dirt from the front part of the head. e. Check the condition of the O-rings 3 and replace them if necessary: the rings should appear elastic and not cracked. f. Check the condition of the insulating diaphragm 7, which can be seen on the front part of the head: clean it thoroughly and eliminate any carbonised remains. N.B.: if the insulating diaphragm is deeply carbonised, it is advisable to replace the head. g. Check the condition of the new inductor support: the insulating diaphragm 6 located between the two metal parts must be complete and not show signs of burning. Replace it if necessary. h. Fit the O-rings 3 and fix the support 2 to the head 1, using the bolts 4. Tighten well to avoid water leakage during operation. i. Turn on the water again and check that there is no leakage.

1 heating head 2 inductor support 3 rubber o-rings 4 support fixing bolts 5 Inductor inductor support

6 insulating diaphragm head insulating

7 diaphragm

Before activating the generator, check that the parts are completely dry. Use a jet of compressed air for this purpose: the presence of water may cause sparks between the two halves of the inductor support, damaging the insulating diaphragm 6. Check that there are no deposits of dirt on the inductor support insulating diaphragm 6 and on the insulating diaphragm 7 visible on the front of the head: these deposits may cause sparks between the two halves of the inductor support, damaging the insulating diaphragm. Use only original CEIA parts.

5.3 - Troubleshooting The self-diagnosis sistem of the PowerCube notifies the operator in case of malfunctioning by means of a series of self-diagnosis messages displayed on the display and with an acoustic signal.

31

5

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 MAINTENANCE

Display

Fault

Cause

Possible intervention

A1

Water temperature too high. The display gives the temperature of the cooling water, alternating to the self-diagnosis message

Malfunction of the cooling unit

Check the temperature of cooling water that have to be less than 50° (intervention threshold =65°C)

A2

Tuning failure

A3

Absence of water cooling

A4

Short-circuit of lead in wire

Contact the technical department of CEIA The flow of cooling water has stopped.

Check the presence of water in the cooling unit. Check the presence of blocking-up in the generator inlets and outlets.

Short circuit in the inductor

Check the absence of short circuit of lead in wires

Small dimensions of the inductor

Increase coil dimensions (see section 6.2.2);

A5

Decrease coil size

Too big dimensions of the inductor

Decrease coil dimensions. Decrease at the maximum the distance between the rims of the head (see section 6.2.2). Diminish the length (centimeter by centimeter). The reduction of the length of the head spouts must be carried out only in the event that the shape of the coil cannot be changed for the type of processing in progress and when the distance between the lead-in wires has been checked

A6

Power circuit failure

Possible breakdown of an internal component

Contact the technical department of CEIA

A7

Disconnected head

Disconnected head

Check the connection between the heads and the electronics unit

A10

Line voltage too low

A11

Line voltage too high

Slave unit not available (PowerCube 64 - Main Unit)

The slave unit is not correctly connected, is turned off, or signals a self diagnosis message (A1 or A3).

Check and, if necessary, reset the presence of the three power supply phases and the correct ignition of the three generator units. In the event that either one or both of the SLAVE units presents a self-diagnosis message (A1 or A3), carry out the related tests as indicated in this table. Check and, if necessary, reset the connection of the CO11 serial cables between the generator units

Communication failure PowerCube 64 – Slave Unit

The SLAVE unit is not correctly receiving data from the MAIN UNIT.

Check and, if necessary, reset the presence of the three power supply phases and the correct ignition of the three generator units. Check and, if necessary, reset the connection of the CO11 serial cables between the generator units

Duty Cycle too high (only on Spectacle Frames Line models)

Continuous activation of the generator or insufficient pause among consecutive working cycles

Start the generator up in an intermittent way

A12

to

Insert (between the mains and the heater) a transformer with an input voltage equal to that available on the line and an output voltage of 220V ~

The SLAVE UNIT display of PowerCube 64 shows only messages A1, A3, A6, A12. 32

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6

6 - APPENDICES 6.1 – Declarations of Conformity CE 6.1.1 – PowerCube 32/900

33

6

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6.1.2 – PowerCube 32/1800

34

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6

6.1.3 – PowerCube 45/900

35

6

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6.1.4 – PowerCube 64/900

36

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6

6.2 - Shape and position of the inductor In order to carry out the soldering as quickly and efficiently as possible, we recommend that these indications be followed: 1. Distance between inductor and pieces to be soldered: it should be remembered that the transfer of heat between these two elements takes place by means of magnetic induction; it is therefore advisable to keep the space between the coil and the pieces to be soldered to a minimum. 2. Shape of the coil: The shape of the coil must follow the outline of the soldering zone. It is also advisable not to use a coil whose dimensions are excessively large. 6.2.1 - Flow of Cooling Water For correct operation the flow must not be less than the minimum for each model as stated in the “Technical Characteristics” section of the manual. The use of inductors constructed with tubes of reduced diameter or of a shape which creates constriction (severely reduced dimensions or sharp bends) may cause a decrease in the flow sufficient to result in inductor overheating. If process requirements necessitate the use of this type of inductor, the water input pressure must be increased, remaining within the limits stated in the “Technical Characteristics” section. The suggested pressure, corresponds to the difference between the input pressure and the output one of the generator. Remove eventual flow slowing down of the water output. There follow some examples of the positioning of the parts: 3

1

Soldering point

2

Heating coil

3

Piece to be soldered

x

Distance between soldering point and coil

1 2

1

3

2

0,1 - 0,3mm 1

1

3

x

3

x

2

2

INCORRECT POSITION OF THE COIL (induttore troppo lontano dal punto di saldatura)

CORRECT POSITION OF THE COIL

37

6

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6.2.2 - Dimensions of the heating inductor The use of an inductor in the correct shape allows the apparatus to operate in the optimum manner and to obtain the best quality of the product. It is recommended the use of silver-plated copper tube. In general, the number of loops is a function of the dimensions of the inductor: Loop diameter

Recommended number of loops

> 8÷9mm

Single loop

< 8÷9mm

Two loops

Examples ø9mm ø1.8mm

20mm

ø7mm ø1.8mm

In general, the shape of the inductor depends on various factors: the type of metal the piece is made of, the shape and size of the piece and so on. The figure illustrates two examples of inductors for special use. Inductor shape

Type of process

Result

10mm ø1.8mm 25mm

20mm 10mm ø1.8mm 30mm

Inductor test To check that the dimensions of the coil are correct, switch on the generator with the piece being worked in position: if the self-diagnosis system does not give either the A4 (coil too small) or A5 (coil too large) message, the dimensions are correct. Inductor for large pieces If the piece being worked is large, it is possible to use a single coil 2 of a suitable size whilst reducing the length of the adductors 1 so as to keep the total value of the inductance within the operational limits of the equipment.

1 2

38

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6

High-power inductor with continuous activation For heavy work (high power and continuous activation) the use of the short adductor is recommended; in this case, use tubes with 2,5-2,8mm diameter. ø3

29

50

65

6.2.3 - Dimensions of the heating inductor The use of an inductor in the correct shape allows the apparatus to operate in the optimum manner and to obtain the best quality of the product. The use of silver-plated copper tubing is recommended. The illustration shows some examples of inductors in general use: 15mm

ø5-8mm ø1.8mm

20mm

8mm ø1.8mm 25mm

6.2.4 - Optimisation of the generator efficiency with small dimension inductors In case the heating inductor has small dimensions, for space and welding reasons (loop diameter lower than 8 mm), the efficiency of the machine can be optimised and the heating times reduced, by spacing the adductor (1 ) out. It is necessary to have a distance of 2,5 mm or more between the two coil tubes. Such distance secures an improved heating power and consequently a reduced heating time. This operation, which is normally not advised for classical generators gives to the PowerCube generator, a higher speed welding outcome.

2.5mm

1

1

2

2 2mm

2 2: heating coil; 4: external supporting parts (brass, steel or aluminium);

4

5

4

5: internal supporting part (ceramic)

Supporting part too big

1: soldering point; 3: pieces to be soldered; Supporting part correct

40

4: supporting part (brass, steel or aluminium)

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6

6.4 - Use of anti-oxidizing gas With the aim of improving the quality of the soldering, it is useful to use distribution valves for the diffusion of anti-oxidizing gas in the soldering area.

1

Soldering point

2

Coil

3

These diffusers should be as close as possible to the heating coil and to the piece being processed, so as to create, during the soldering, an oxygen-free "chamber".

4

The end part of the diffusers should be constructed in non-metallic material (for example, teflon), in the event that such parts come very close to the coil.

5

Pieces to be soldered Gas diffusers

End part of the diffuser in non metallic material (teflon)

There follows an example of an installation with gas diffusers.

6.5 – Control via RS232 serial interface The generators of PowerCube family, can be managed through the use of a serial line, using a Terminal or a Personal Computer. 6.5.1. Setting of the Terminal Connect the RS232 port of the For this connection a serial communication cable (CEIA PowerCube to a terminal configured with code 19623) may be used). the following line parameters: Power Cube

Baud rate parity data bit stop bit flow control

: 9600 : no parity :8 :1 : non

3 2 5 9p

Personal Computer 2 3 5 9p

6.5.2. Starting of the connection On the terminal keyboard, press "Ctrl-Z": on the screen the character ">" will appear (should it not appear, repeat the operation).

41

6

FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64 APPENDICES

6.5.3. Commands The commands available are the following: Syntax H1 H2 S1 S2 P1 P1=xx P2 P2=xx

PW _RO

Description It activates the head 1 of the generator It activates the head 2 of the generator It stops heating at head 1. It stops heating at head 2. Reading of the working power pre-selected for the heating head 1: a value from 10 to 99 is displayed which has to be intended as percentage of the maximum power. The working power for the heating head 1 must be set at xx, being xx between 10 and 99. The pre-selected power can be varied only when the heating head is not activated. Reading of the working power pre-selected for the heating head 2: a value from 10 to 99 is displayed which has to be intended as percentage of the maximum power. The working power for the heating head 2 must be set at xx, being xx between 10 and 99. The pre-selected power can be varied only when the heating head is not activated. Reading of the power supplied: a value from 10 to 99 is displayed which has to be intended as percentage of the maximum power or -- if none of the two heating heads is activated. Reading of the external signalling relais status

Setting of the operative mode for the external signalling relais: Possible values are AL and ON. with _RO=AL (default), the relais indicates the generator alarm status, _RO=xx opening the circuit in case of alarm or generator not powered. with _RO=ON, the relais closed the circuit in presence of generator output power.

SC

Reading of the POWERCUBE state : in the event that none anomalous situation is present OK is the answer displayed, otherwise a diagnosis code Ax will be displayed, having x between 1 and 12 showing an anomalous situation. See on section MAINTENANCE of the PowerCube instruction booklet for the codes meaning comprehension.

in case of wrong syntax, out of range parameter or unrecognised command, the controller will show the message: ???

42