User manual
Contents
1. 101 E User manual MV QUINCY E 2 Identification of the machine 2 Product SCCM CATO INS sexag xxu XY ew do Era a 2 Dimensions and weight 2 Normalve ER 2 USING 3 General notes 3 Recommendations Of 3 Constructions Te Ab BS ssec cicuta DUE quP FEM UD ENIM 4 Signs and warning SIGNS 4 LISEOI eorr 4 Control panel GESEMDUON 2 Eu 5 NISC 6 FSS 6 NOISE Vibrations 6 PENON aid dS PO EE 6 Unpacking and installation 6 Electrical connection 6 Jona the MOCNO secos 6 Repiscihd the ICC DO MS 6 ere Su NF ERU MN FUE Electrical aar EUN EYE 8 56 12. Components and parts This section contains a list of the components of this machine Its contents may be used for identification of spare parts For rapid delivery of spare parts please quote the following order 1 Number in the list 2 Part number design or commercial 3 Name of part 4 Quantity 5 Serial number of the machine 6 Date of manufacture 053472 18 04 2014 V2 10 Powerduction 1601 D ROHS CERTIFICATE OF COMPLIANCE Directive 2002 95 EC of the European Parliament and of the Council of 27 January 2003 on the restriction of use of certain hazardous substances in electrical and electronic equipment GYS declares that The POWERDUCTION 160L complies with this directive and does not contain concentrations that exceed the limits for the following substances Lead Pb Mercury Hg Cadmium Cd Hexavalent chromium Cr VI Polybrominated biphenyls PBB Polybrominated diphenyl ethers PBDEs CE DECLARATION OF CONFORMITY GYS certifies that the product POWERDUCTION 160L is compliant with the following directives and standards The Low Voltage Directive CE 2006 95 Machinery Directive 2006 42 EC EMC Directive 204 108 EEC Directive 200 2 95 CE EC Directive 2002 96 Directive CE2004 40 Exposure to electromagnetic fields C Changes which would have effects on the technical specifications of the product and affect the use in conformity with the user manual make this decla
3. PHA EES 9 Cooling liquid circuit diagrams cene 10 ROHS declaration of compliance 11 CE declaration or conformity uosaexsa wies ancor n ea ct sk AGE CEDE 11 053472 18 04 2014 V2 be Powerduction 1601 D WARRANTY Upon delivery the buyer will have to make sure that the machine is complete Deficiencies and anomalies must be reported Any attempt to change any part of the machine CE marking the declaration of conformity and or the manufacturer s declaration will invalidate the warranty The manufacturer is also considered exempt from liability arising from the following cases Incorrect installation Improper use of the machine by personnel not adequately trained Safety regulations not respected Lack of maintenance Modification of the machine or use of non original parts for repair IDENTIFICATION OF THE MACHINE An identification plate can be find at the back of the machine on which in addition to CE marking is reported Name and address of the manufacturer Date of manufacture Model Type of machine Weight e Voltage These data must be mentioned whenever it requires technician s intervention or spare parts request PRODUCT SPECIFICATIONS Induction heater Power 16 0 kW Voltage 400 V Mains frequency 50 Hz Heater frequency 15 kHz Insulation Class IT No of poles 3 Cooling liquid provided Standard automot
4. The machine is supplied ready to use Before operating you must remove all packaging and place the product in a suitable place flat ground dry and ventilated place WARNING The installation must enable easy access to all of the machine s parts A minimum space around the product must be respected for good operation and maintenance without problems and risks for the operator Replacing the inductor WARNING The replacement of the inductor should be performed only by authorized staff and only after switching off the machine WARNING During maintenance and or repair wear protective gloves Electrically isolate the machine by disconnecting it from the mains WARNING It is forbidden to start using the machine if all the metallic side panel have not been screwed back on the product and if all the safety features are not operational 053472 18 04 2014 V2 6 Powerduction 1601 D WARNING This machine has been designed to reduce at the maximum the risks relative to exposure to electromagnetic fields However residual risks may remain and therefore it is recommended to respect a minimum safety distance of 30cm between the inductor and the head or the chest of the operator MAINTENANCE General recommendations e t is essential that the maintenance of the machine is carried out by qualified and authorized personnel which is aware of the recommendations described in this user manual e Never perform any cleaning lubri
5. button 6 blinks indicating that the product is ready to heat Position the inductor 8 flat on the part or the area to heat up placing the open part of the ferrite against the part Press the trigger 7 on the handle of the inductor to start heating if necessary move the inductor in order to heat up a larger surface on the part After stopping the heating decrease the heating power level on the control panel and secondly only switch off the product this way the cooling circuit will reduce the temperature of the inductor before switching off completely the product RESIDUAL RISKS WARNING The machine has been designed to ensure maximum safety It s still possible that the operator may get burnt by touching hot parts WARNING The machine must not be used near sensitive materials or dangerous explosives compressed gases flammable liquids electrical equipment Metal objects may not be worn close to the inductor as they will become hot rings for example It is forbidden for people wearing pace makers or any other biomedical equipment to use this product Noise and vibrations The machine produces a continuous sound level of less than 60dB A The machine does not generate significant vibrations that may cause danger Destruction and disposal Some materials with which the machine is built can be recycled therefore recycling the product should be performed in accordance with relevant local regulations Unpacking and installation
6. cation or maintenance with the machine running e Before any maintenance work turn the ON OFF switch on 0 to turn the machine off unplug it from the mains to avoid electrical shock or other hazards resulting from mishandling e Do not wear rings watches jewellery dangling clothing such as ties torn garments scarves unbuttoned jackets or zip open that can be caught during operation e Instead wear suitable clothes for accident prevention for example non slip shoes anti noise headphones goggles appropriate gloves etc e Never use petrol or flammable solvents to clean the machine Use water and if needed commercial non toxic solvents e After maintenance always put back the metallic side panels of the machine before turn it on Preventive Maintenance Meticulous inspections carried out at regular intervals of time are necessary in order to detect and solve faults quickly before they can cause damage A WARNING Every time using the POWERDUCTION 160L check first the safety features of the product and any anomaly which could lead to bad operation Check daily wear of the machine WARNING The operational safety of the machine can only be guaranteed if repairs are carried out using only the original spare parts and if approved maintenance instructions are carried out correctly After each use with the machine turned off the machine should be cleaned promptly to remove dust or dirt in general because they may dec
7. ent amendments In particular given that the operator is in direct contact with the machine e Remove sharp edges and sharp angles e Place the machine in a stable position e Ensure that the operator cannot come into direct contact with live parts which may cause electrical shock or injury And everything else needed to secure its use The main parts of the POWERDUCTION can be summarized as below 1 ON FF switch x Pd a 2 Control panel d Fd 2 3 Inductor 4 PCB fee et 5 Fan 6 Cooling unit 5 4 Signs and warning signs 3 Protections On the machine are placed signal warnings and mandatory warnings that the operator must follow for his personal safety and security The machine is safe to use however it is recommended to be careful during operation as heated materials can burn on contact for a long time after the passing the inductor The inductor itself even if continuously cooled may become warm on red heated parts and therefore there is a risk of burns The machine is equipped with several electronic protection systems against electrical surges and overheating The thermal protection of the inductor mainly occurs when heating parts in metallic alloys To restart the machine release and press again the button For all the other protections switch off the product using the ON OFF switch Finally there are 2x 32 A fuses on the heating circuitry fuse holder under the metallic co
8. ive cooling liquid water 3096 max glycol Power lead 10 m Inductor cable 4 m DIMENSIONS AND WEIGHT Weight 190 kg height 1100 mm 96 mm wheels Width 500 mm Depth 600 mm NORMATIVE REFERENCES Directive CE2004 40 Exposure to electromagnetic fields Low Voltage Directive CE 2006 95 Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Directive 2002 95 EC EC Directive 2002 96 053472 18 04 2014 V2 ns Powerduction 1601 D USING THIS USER MANUAL It is very important that this user manual designed to provide user with general knowledge of the machine as well as instructions for use and maintenance necessary for operating is kept with the machine or in a safe place for future reference The user manual as mentioned by the law is an integral part of the machine and must be with it until its destruction The warnings given must be read carefully for safety reasons before installation and use It is prohibited for any reason to modify this manual without the written permission of the manufacturer GENERAL SAFETY NOTES The machine is designed for a professional use Its durability and reliability will be more effective if it is correctly used and regular maintenance is done Always read the instructions contained in this manual they provide important safety information RECOMMENDATIONS OF USE This machine should be used only for the purpose for which it has been designed heating metals Any other u
9. ration of conformity not valid 05 08 2013 Nicolas BOUYGUES GYS Pr sident Directeur G n ral CEO 134 BD des Loges 53941 Saint Berthevin Aus CA U Sco oat 053472 18 04 2014 V2
10. rease ventilation and alter the proper functioning of the product and its durability Before each use check every control of the machine work safety devices and the electrical connection cables WARNING Make periodic visual checks to verify that there are no leak and the vents are clear 053472 18 04 2014 V2 ags Powerduction 1601 D ELECTRICAL CONNECTIONS The product has been designed for 400V 50 Hz three phase electrical supply WARNING do not use on a 60Hz electrical supply On a three phase 400V electrical supply connect the pins as shown below P3 P2 POWERDUC TION 160L P1 Terre Earth A specific order has to be respected when connecting the 3 phases If this order is not respected the PHASE ALARM LED will switch ON Modify the order of the phases until the PHASE OK LED switches ON 053472 18 04 2014 V2 Bos EM e Co q C dd J O San ELECTRICAL DIAGRAMS Lice Co AFE mpl ul uer poss F ro Se TORO did qae auo zi PEM 2182005 053472 18 04 2014 V2 Powerduction 1601 D COOLING LIQUID CIRCUIT DIAGRAMS Fan 1309000304 Radiator 1309000301 Thermostat 1309000406 Ind ct r Junction box 1109000218 Flow detector 1109000413 Pump 11090003023 Tank 1309000302 Inductor 1109000215
11. se not expressly mentioned in this manual is strictly forbidden and dangerous The machine is semi automatic and requires the presence of the operator WARNINGS The operator has the responsibility to respect not only for him but also those who may be exposed to the risks of the machine all the rules that relate to safety Before performing any operation with the machine carefully read this manual as it gives guidelines and procedures to operate the product correctly and safety e The machine must be only used by trained operators and in full compliance with local regulations and instructions contained in the manual Strictly follow the signs and mandatory warnings on the machine Before any maintenance electrically isolate the machine to prevent accidental In case of damaged or broke of cooling hoses or electrical cables act promptly to replace them In case of cooling liquid leaking the floor must be cleaned to avoid risks of people falling Do not leave the equipment exposed to bad weather rain wind etc Do not leave the equipment unattended with children around If you decide not to use the equipment make it inoperative and respect practice related to disposal in accordance with law 053472 18 04 2014 V2 jue Powerduction 1601 D MANUFACTURING FEATURES The machine is designed and built in compliance with the essential health and safety requirements laid down by the Machinery Directive 89 392 EEC and subsequ
12. ver of the product The fuses should only be replaced after the default has been repaired 053472 18 04 2014 V2 T Powerduction 1601 CONTROL PANEL DESCRIPTION 11 6 9 5 10 4 3 2 1 ace 061 cE CG AM Z AAA General ON OFF switch Power setting buttons Power indicator 1kW 16 kW Induction heating activation Alarm indicator Cooling circuit Heating indicator ON heating blinking stand by racore temperature alr machine stopped _ Alarm indicators The alarm indicators above mean from left to right 1 A cooling liquid temperature which is too high Leave the product ON without using the inductor in order for the cooling liquid temperature to decrease 2 An issue with the flow of cooling liquid pump issue blocked pipe 3 A defective inductor contact GYS after sales or your local distributor Note in case of alarm the product does not heat up 053472 18 04 2014 V2 Powerduction 1601 D INSTRUCTIONS OF USE The product is delivered with a three phase 400V 50 Hz plug In order to ensure an optimum use the product should be connected to an electrical installation with minimum 25A protection and protected according to applicable standards See the instructions for electrical connections on page 8 Turn the ON OFF switch to the ON position Press the induction heating activation button 4 described on page 5 The light on
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