Desktop Melter User Manual - Ultraflex Power Technologies
Contents
1. UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 ef O UL ILI IS Water Flow 28 gt min Figure B7 SYSTEM Menu Structure Version 1 2 23 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 B3 4 4 EXTENDED MENU Navigation EXTENDED MENU is accessible from Heat ON Menu by pressing SELECT button For 2seconds It is shown on Figure B8 This menu allows additional basic inverter parameters to be shown power current voltage frequency OUTPUT VOLTAGE Version 1 2 24 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 a UPT 016 500 510 520 00 o aD Power Set Point SELECT 225 me Lil tL gt 00 lt gt om TEMPERATURE iH LI N Figure B8 M enu Structure Version 1 2 25 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 B3 5 CONTROL MODES Control M odes of Operation There are two control modes of operation Auto In this mode device automatically holds up previously set temperature of the crucible In this mode thermo regulator is switched ON see Fig B7 Manual In this mode it is supposed tha2. 14 to avoid condensation e Minimum water flow is required Refer to product specifications in Section B e Water coolant must be mechanically debris free e Water coolant must be chemically pure distilled water is recommended A2 5 ACINPUT CONNECTION The Power supply connects to the power network through an 6 ft 1 80m power cord supplied Additional fuse or circuit breaker and residual current circuit breaker on that power branch is a good choice since it will provide extra protection in addition to the unit s internal protection A mechanical switch is also recommended within the operator s range and vision and possibly closer to the Power Supply Only trained personnel should open the unit cover and operate the breakers Table A1 Wiring Color Code Color 1 Phase Connection 3 Phase Connection Brown Line 1 Line Blue Neutral Neutral Green Yellow Ground Earth Ground Earth Version 1 2 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 NOTE Local codes may have stringent requirements It is the customer s responsibility to be familiar with and to comply with all applicable codes concerning conductor ratings and wiring procedures An electrician familiar with the local regulations should determine proper wiring connections A2 6 START UP 1 Connectthe AC and ground connections as described in Section A2 5 2 Connect the water cooling system to the device 3
3. 2 kg gold Graphite Crucible 1 4 4HVM 000 102 00 Crucible tong 1 1 1 Fig C2 Accessories Revision Table ne Ner Date Remark ibi 1 AO 01 2011 Original L Mihova Add Water Filter Unit Revision A10 Current Water Flow in System M enu 2 Al 072011 After Rev 1 10 L Mihova Add Chapter A2 7 Using the Machine Add Electronic plate assembly spare parts diagram B1 5 3 1 0 12 2011 Add Table B4 Device Spare Parts List Table B1 5 L Mihova Minor changes in title and footer 4 11 04 2012 New Design D Deneva Minor changes in heder and name Inverter board from 5 12 062012 140p 016210 00 to 1M OD 751 220 00 Version 1 2 28 www ultraflexpower com
4. 7 1 450 x 360 x 180 feet Weight 38 Ib 18 kg Net weight Connections B1 3 CONNECTION DIAGRAM Version 1 2 www ultraflexpower com 13 UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 Figure B2 Rear Panel Connections Table B2 Rear Panel Connections Table 10 Description Water outlet Water inlet Power line fuses Power line switch Power line cable GI NO mnm Water filter 1 4 DEVICE SPARE PARTS DIAGRAM Version 1 2 14 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 Figure B3 Device Expanded View Table B3 Device Spare Parts List Table No Name Part Number 1 Front Side Easy 2M AS 016 500 AC 2 Partitioning Wall Easy 2M AS 016 500 Al 3 Induction Coil UPT 016 520 1ASM 016 501 00 UPT 016 500 510 1ASM 016 502 00 4 Ceramic Plate base 2DET 016 500 KN 5 Refractory Ceramic Base 2DET 016 500 KL 6 Feet AHVM 000 017 00 7 Thermocouple 3SNM 000 003 00 8 Left Side Panel Easy 2M AS 016 500 AE 9 Fan 60x60x15 3FAN 012 002 00 10 Rear Panel Easy 2M AS 016 500 AG 11 Flow switch 9VLO 000 054 00 12 Water Fittings 2DET 016 500 KM 13 Water Filter 9VLO 000 125 00 14 Main fuse holders 3FFT 000 016 00 15 Cable Gland AKVT 000 021 00 16 Main Switch 3SBT 000 018 00 Version 1 2 15 www ultraflexpower
5. WP ultraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 Desktop Model Easy Melt 0 5 1 2 kg Part Number UPT 016 500 510 520 00 User Manual Version 1 2 1 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 TABLE OF CONTENTS SECTION A GETTING STARTED GUIDE a ERE A RC daana 4 A1 SAFETY INSTRUCTIONS iss ciiin rini tii nr ccn c er c a cn cr 4 A11 IMPORTANT NOTES isicicisa iri rcr rir rcr nc n c n re 4 1 2 SAFETY PRECAUTIONS rr E rr 5 A1 2 1 ELECTRICAL SHOCK HAZARDS nnns 5 1 2 2 QGROUNDING iso siii naar nri ri o ac nr er nir c rei 5 A1 2 3 SAFETY AND PRECAUTION SYMBOLS USED IN THIS M ANUAL 6 A2 INSTALLATION AND 5 erre nennen n 7 A2 1 INSTALLATION PROCEDURE irc irr rnc oic rae 7 A2 2 UNPACKING 22 eo rcc ccce 7 A2 3 SELECTING rivi pcnc c a RR 8 A2 4 COOLING REQUIREMENTS escccixinizi einkz ir enirn p Er pinna Erin prO E unn 8 A2 5 ACINPUT CONNECTION iississcsx iieri tiic noue ooda nica nunmehr enata nens 8 A2 6 START UP icis oar rbi tonar con eronaton anie neran datar n nter 9 A2 cox aaa ccn ata ed nl 9 A3 MAINTENANCE ciiin rixa ixi era n nona cata
6. and assumes no responsibility for any errors that may occur in this manual 6 Safety First A YOU AND NOT THIS M ANUAL ARE RESPONSIBLE FOR ALL SAFETY PRECAUTIONS This manual is for reference purposes only Personnel should be trained on proper operation of this equipment before using Only authorized personnel may perform any troubleshooting or repair on any UPT manufactured equipment Failure to comply will void warranty Please contact the UPT Service Department before servicing any UPT equipment Lethal voltages may be present in equipment surrounding and or connected to this equipment Read the following warnings carefully and study this entire manual before operating the system Failure to observe warnings may result in equipment damage serious personal injury or death If the equipment is used in a manner not specified by this manual the protection provided by the equipment may be compromised and damage to the unit may occur 1 Only qualified persons who have been trained in the operation of this equipment and are familiar with the technology should be permitted to operate the system 2 Installation assembly inspection maintenance and servicing are to be performed by authorized personnel only 3 Always have the Power Supply completely powered OFF and locked out before performing any service inspection or maintenance 4 Even with the Power Supply OFF live voltages still exist within the cabinet Always power OFF and loc
7. com UltraFlex EasyM elt 0 5 1 2 POWER TECHNOLOGIES UPT 016 500 510 520 00 17 Refractory Protective Cover 2DET 016 500 KQ 18 Metal Protective Cover 2DET 016 500 KH 19 Bracket for Tank Cap 2DET 016 500 LB 20 Tank Cap 3CFM 105 001 01 21 Right Side Panel Easy 2M AS 016 500 AD 22 Electronic plate assembly 1ASM 016 500 00 23 Holder Coil 2M AS 016 500 AM 24 Output transformer UPT 016 520 2M AS 016 500 DC UPT 016 500 510 2M AS 016 501 DC 25 Control panel 1ASM 016 540 00 B1 5 ELECTRONIC PLATE ASSEMBLY SPARE PARTS DIAGRAM Figure B4 Electronic Plate Assembly Expanded View Table B4 Device Spare Parts List Table Ne Name Part Number 1 Base electronics easy 2M AS 016 500 AK 2 Choke assembly 1ASM 722 169 00 3 Control board 1M OD 722 700 00 4 Inverter board 1M 00 751 220 00 5 Water heatsink 2DET 016 500 KV 6 Rectifier inrush limiter 1M OD 751 600 00 Version 1 2 16 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 DS UPT 016 500 510 520 00 7 Heartsink rectifier 2DET 016 500 KR 8 Line filter 3FTM 000 007 01 B2 HEAT STATION SPECIFICATIONS B2 1 PRODUCT OVERVIEW Heat Station It is a part of the device placed into the same cabinet with HF power supply It houses the output circuit and interfaces it with the load by means of an induction coil The Heat station consists of an ou
8. light fig B4 4 will go on and the machine will heat according to the set power It is possible to increase or decrease the power during the melting process by pressing the power button previously selected by the SELECT fig B4 10 button During the cycle on the display fig B4 5 you will be monitoring the temperature A3 MAINTENANCE A3 1 SCHEDULING The Power Supply is designed for continuous service and minimum maintenance requirements The frequency of any maintenance program is a function of environment degree of equipment use and product experience A3 2 PERSONNEL Qualified personnel must perform inspection and maintenance procedures only Personnel must read and be thoroughly familiar with all safety precautions discussed in this manual A3 3 INSPECTION AND MAINTENANCE PROCEDURE Note Always follow approved lock out tag out procedures before performing any service inspection or maintenance The following describes inspection procedures to be performed on a daily weekly and monthly basis Daily Weekly Inspection It is good practice to do a quick visual inspection of the unit wiring and connections on a daily and or weekly basis Report any apparent changes in performance to responsible personnel so that potential problems can be investigated Monthly Inspection Perform the following on a monthly basis 1 Ensure all wiring connections are secure Visually inspect for any wear on cabling 2 Verify that none
9. of the enclosure s hardware has become loose 3 Remove any build up debris that may occur around the fan inlet using a cloth or a vacuum cleaner Use of compressed air is not recommended 4 Checkthe water coolant for mechanical debris or impurities The water should be kept clean 5 Wipe the Control Panel with a damp cloth to remove any dirt prints or smudges 6 Wipe the enclosure down with a damp cloth or paint friendly cleaner if desired 7 Unbolt water filter clean it and bolt carefully again Version 1 2 10 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 016 500 510 520 00 A4 SERVICE A4 1 GENERAL If for some reason the unit fails in the field it is advisable that the unit be serviced by the manufacturer or its authorized service representative Should that happen please contact us immediately see contact information in Section A4 2 Please have the following information about your unit available upon calling Unit Model and Revision located on the label on the back of the unit Unit s Serial Number located on the label on the back of the unit Line Voltage and frequency Detailed description of the problem encountered including load ambient temperature at the time of the failure Detailed description of the actions taken Approximate time in service gt If our technical staff is unable to help you over the phone then a repair authorization number will be
10. this M anual for optional equipment and Accessories Version 1 2 12 www ultraflexpower com UltraFlex POWER TECHNOLOGIES B1 2 DEVICE SPECIFICATIONSTABLE Table B1 UPT 016 Easy Melt Specifications Table EasyM elt 0 5 1 2 UPT 016 500 510 520 00 RATING DESCRIPTION SPECIFICATIONS CONDITION UPT 16 500 UPT 16 510 UPT 16 520 INPUT AC Voltage range 230 VAC 510 Single Phase Line Frequency 50 60 Hz Ce 7304 12 15 5 230 VAC 10 Input Power maximum 2 kVA 2 55 kVA 3 2 KVA 2 230 Efficiency minimum 8896 9 full load OUTPUT Control M odes Constant Power with voltage and current limit Output Current maximum 13A sine wave 9 10096 current reference Output Voltage maximum 250 RMS 9 230 10 Input Output Power maximum 1 5 KW 2 0 kW 2 5 kW 9 230 VAC Input Output Frequency range 30 60KHz 9 2 0kW Timer Resolution lmin step 1 30 PROTECTION Over current 20 A RM S Inverter output current Over temperature heat sink 55 Reset by depressing STOP MISCELLANEOUS 32 F 0 C to 104 F 40 Operating Temperature Ranges 4 F 20 C to 150 F 65 C Storage RH Non condensing Humidity range 0 to 95 Operating amp Storage PHYSICAL 0 5GPM 2 LPM minimum Cooling Forced water water flow Maduie Dimensione W xDxH in mm Overall dimensions with 17 7 x14 2 x
11. FAULTS AND WARNINGS nnn 26 C3 ACCESSORIES 2 0 eere ErE ERE EFE FERE FERE FEE FEE aaka 28 Version 1 2 3 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 SECTION A GETTING STARTED GUIDE A1 SAFETY INSTRUCTIONS A1 1 IMPORTANT NOTES 1 This manual is valid only for the Model and the associated Revision number s specified in the cover sheet of this manual A Change Page may be included at the end of the manual All applicable changes are documented with reference to the equipment Revision and Serial number Before using this Instruction M anual check your equipment nameplate to identify your Model and Revision number If in doubt contact your nearest Ultraflex Power Technologies UPT Corp Representative 2 This document contains information proprietary to UPT Corporation All rights are reserved No part of this document may be reproduced transmitted processed or recorded by any means or form electronic mechanical photographic or otherwise nor be released to any third party without the express written consent of UPT Corporation 3 In this document period will be used as a decimal point delimiter 4 Data subject to change without notice 5 All Information contained in this manual is the latest information available at the time of printing The right is reserved to make changes at anytime without notice UPT Corp makes no warranty of any kind with regard to this material
12. ND SYSTEM STATUSES Device works in power regulation mode only Version 1 2 19 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 B3 4 MENUS AND NAVIGATION B3 4 1 Main Menu Navigation POWER ON Control Panel SW Revision 22 2 Y T gt nio Output Power r Change Power Set Point Thermo Regulator EATON e Set Point Figure B5 Main Menu Structure Version 1 2 20 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 un UPT 016 500 510 520 00 B3 4 2 Heat ON Menu Navigation HEAT ON Menu is accessible from M ain M enu by pressing START button It is shown on Figure B6 Change Power Set Point I I Temperature C 5 q I I I e Figure B6 HEAT ON Menu Structure Version 1 2 21 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 B3 4 3 SYSTEM MENU Navigation SYSTEM MENU is accessible from M ain M enu by pressing SELECT button for 2 seconds It is shown on Figure B7 Control Panel SW Revision Control Board SW Revision Thermo Regulator ON Down Button 1 2 Thermo Regulator OFF a Version 1 2 22 www ultraflexpower com
13. Turn the water Cooling System ON Make sure there is no water leaks on outside connections 4 Turn the Power Switch on to power the system Check for any Fault or Alarm messages If the status screen shows 8096 Power message then the system is ready for operation See Section B of this Manual for Connections Diagrams A2 7 USING THE MACHINE 1 Using a water hose connect the machine to the water source for the cooling In the back of the machine you will find the connections water in fig B2 1 and water out fig B2 2 The connection to a water tap is enough but the used water will be thrown away A connection to a water tank with a circulating pump is also possible as well asto a chiller with controlled temperature Remember to tight strongly the hose on the connections with a clamp 2 Connect the machine to the electric supply 220 V single phase 3 Crucible Check that your crucible is good enough to make a melting A too much used crucible can make the casting very slow Check also that the bottom is not too thin you risk that it brakes during the melting causing the metal going out 4 Place the crucible in the melting chamber paying attention to the thermocouple positioned on the bottom The purpose of the thermocouple is to read the temperature of the crucible For this reason the crucible has a hole underneath to let the thermocouple to touch the graphite 5 Switch on the machine pressing the main switch fig B2 4 positione
14. d on the back of the machine 6 Onthe control panel you have the possibility to adjust three parameters 7 Power efficiency This parameter determinate how fast the melting will be done We suggest to use 80 power in order to have a more homogenous melting 8 Time This timer will start to count the set time when the furnace will reach the set temperature It is going from 1 to 30 minutes At the end of the time a buzzer will ring for a half second then the furnace will stop to heat The purpose of this timer is to let the metal to be completely molten and mixed after the heating If you don t like to use the timer set it in OFF position 9 Temperature Set the melting temperature the maximum suitable value is 1 300 10 Choice of parameters In order to choose the parameters push the SELECT fig B4 10 button The red light fig B4 6 7 8 will move to the parameter you want to modify With the help of the arrows fig B4 9 you can increase or decrease the value till when you will find the desired value by checking on the display fig B4 5 11 Melting Put the metal in the crucible and push the START fig B4 2 button 12 In case you want to stop the machine push the STOP button fig B4 1 13 If something is wrong the machine will go in ALARM and the red light fig B4 3 will go on Version 1 2 9 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 14 The heating will start the
15. e Heat Station is provided e Connecting accessories or interfacing the system with other controls if necessary e Completing the Power and Ground Earth connections Power and ground earth connections must be made last Failure to do so will create a hazardous condition that may result in equipment damage personal injury or death NOTE UPT Corporation has a staff of field engineers who are available to supervise the installation of the equipment If installation service is required contact our Technical Service Department for additional information Provisions for facility electrical power service are customer furnished Requesting field engineering assistance before customer furnished provisions are installed at the equipment site could delay equipment installation and cause unnecessary expense A2 2 UNPACKING AND INSPECTION This equipment has been thoroughly inspected and tested prior to packing and is ready for operation After careful unpacking visually inspect for shipping damage BEFORE attempting to operate If any indication of damage is found file an immediate claim with the responsible transport service and advise your sales representative Inspect equipment before installing Damaged equipment may result in improper operation and create a hazardous condition resulting in personal injury or death Inspect equipment before installing Damaged equipment may result in improper operation and create a hazardous condition resultin
16. enananaent nennen nator adn 10 A3 1 SCHEDULING 10 2 PERSONNEL 2 axisixpit rmn nein porn orar br ED con Eno n Ex OE EUER E DUE ERN 10 A3 3 INSPECTION AND MAINTENANCE PROCEDURE nnns 10 A4 SERVICE qe M 11 4 1 GENERA We 11 A4 2 SERVICE CONTACT INFORM ATION 11 SECTION B PRODUCT SPECIFICATIONS AND FEATURES nnn 12 B1 POWER SUPPLY iR tix EG X Errata n dns 12 1 1 OVERVIEW hd ER 12 1 2 DEVICE SPECIFICATIONS TABLE sistsssessssacistsascrisesesaransctsanaancisnsarasteasivasasesivanserinn 13 B1 3 CONNECTION DIAGRAM PERSE SEE ITE EUG DOC FREE EE 14 B1 4 DEVICE SPARE PARTS DIAGRAM 15 1 5 DEVICE ELECTRONOCS SPARE PARTS DIAGRAM nnn 16 B2 HEAT STATION 17 B2 1 PRODUCT OVERVIEW 5 rci ri ciii in ir in riv redii vau 17 B2 2 HEAT STATION SPECIFICATIONS 5 55
17. g in personal injury or death Version 1 2 7 www ultraflexpower com UltraFlex POWER TECHNOLOGIES EasyM elt 0 5 1 2 UPT 016 500 510 520 00 A2 3 SELECTING THE DEVICE SITE Consider the following when choosing a location for the device e Make sure the system is installed in a debris free zone e The device has to be connected to a power source and cooling water e The device have to be connected to cooling system with sufficient water flow Make sure the device is easily accessible by the operator e Device has to be seated on a mechanically secure surface A2 4 COOLING REQUIREMENTS The power transistors and rectifiers into the device are maintained within their safe operating temperature range by means of water cooling The fan inlets must be kept clean from obstructions in order to insure proper air circulation If installed in confined spaces care must be taken that the ambient temperature the temperature of the space immediately surrounding the device does not rise above the limit specified as 40 Periodic cleaning of the device exterior is recommended The following system components are directly dependent on water cooling semiconductor s heat sinks coils tank capacitors output transformers To maintain the temperature on these components within safe limits the following requirements apply to the inlet cooling water e Maximum allowable temperature 95 F 35 e Minimum allowable temperature 58 F
18. issued for you With this number enclosed in you return package you can ship the unit back for repair or request a service engineer to repair the unit on site A4 2 SERVICE CONTACT INFORMATION For technical service questions please call Europe and Asia 359 2 480 1900 USA and Canada 1 631 467 6814 You may also fax your questions or request Europe and Asia 359 2 480 1910 USA and Canada 1 631980 4065 Or e mail us at support ultraflexpower com You can also send you request through our web site Note Please include your contact information so that you can be easily reached if necessary Version 1 2 11 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 aud UPT 016 500 510 520 00 SECTION B PRODUCT SPECIFICATIONS AND FEATURES B1 POWER SUPPLY SPECIFICATIONS B1 1 OVERVIEW The UPT 016 500 510 520 is a general purpose induction heating system designed to work with a large variety of custom coils It consists of two main parts placed into the same cabinet They are l Power supply generates RF power to supply the output circuit 2 Heat Station houses the output circuit and interfaces it with the load by means of an induction coil The unit is digitally controlled through a control panel located on front panel Figure B1 Overall Device Dimensions Notes 1 A tool is required to gain access to the Power Supply This isto prevent accidental exposure to the internal high voltages 2 See section C of
19. k out the external power source to ensure no one can accidentally energize it Version 1 2 4 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 5 Ensure that all external wiring conforms to applicable codes 6 Obey all warnings and use good common sense A1 2 SAFETY PRECAUTIONS A1 2 1 ELECTRICAL SHOCK HAZARDS This manual is written for personnel familiar with the technology pertaining to the operation of induction heating equipment Such personnel should be thoroughly familiar with the hazards associated with this equipment and electrical equipment in general and they should have received proper safety procedure training Hazardous voltages are present within this product during normal operation The product should never be operated with the cover removed unless equivalent protection of the operator from accidental contact with hazardous internal voltages is provided Operators must be trained in its use and exercise caution as well as common sense during use to prevent accidental shock There are no operator serviceable parts or adjustments within the product enclosure Refer all servicing to trained service technician A Source power must be removed from the product prior to performing any servicing This product is designed for use with nominal a c mains voltages indicated on the rating nameplate 1 2 2 GROUNDING This product is a Class 1 device which utilizes protective grounding to earth to ens
20. power com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 Table B5 Control Panel Components Function Description Indicator Control Stop Button dual function Stops the heating cycle when the device is 1 Stop Button in Heat on state CONTROL Resets any faults when the system isin Alarm state 2 Start Button Start Button activates the heat cycle CONTROL LED Green when LED Green Illuminated when HF generator generator is heated ON is heated ON PISTES 4 Large 7 segment LEDs display Output set point Timer min or OFF Temperature 5 2 Inverter current Arms INDICATOR PER Inverter output voltage Vrms Inverter output power kW Output frequency kHz LED RED Illuminated when Indicator 4 6 LED RED timer status INDICATOR 7 LED RED output set LED RED Illuminated when Indicator 4 INDICATOR point in 96 shows output set point in LED RED output set LED RED Illuminated when Indicator 4 point in shows output set point in in 9C INDICATOR UP and DOWN arrow buttons dual 9 UP DOWN arrow function CONTROL buttons changing value of parameters scrolling through the menus SELECT button 10 SELECT button scrolling through the parameters entering CONTROL menus and confirming parameter s value B3 3 REGULATION MODES A
21. r range during Heat On shorted turns Check fans blockages of the Er4 PS Over Theat sink gt 60 C 2 2 vents or fan filters Cooling Temperature p water temperature water the max allowed T filters Can t find resonant Check escheat loop Appearance only connections load coil tank frequency or the Er5 Auto tune fault in service mode capacitors Transformer taps frequency is out of dup after sweeping range Possible inverter board Part Number M OD 016 210 failure Communication Communication Error Between N 5 Check cables and RS connectors Er9 received after the last Fault Panel and Control between boards command Board Check cooling water flow rate and water pressure Check Er28 Water Flow Fault SENG arer hoses and external water filter for blockages Check flow switch Temp of the Crucible Crucible is 150 C Check Thermocouple and thermocouple or THi Temperature higher than Thermocouple cables and thermocouple Over Regulation Thermo regulator connections connections Set Point Version 1 2 www ultraflexpower com 27 UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 C3 ACCESSORIES Table C2 Accessories Table Melter No Part Number Description UPT 016 500 UPT 016 510 UPT 016 520 0 5 kg gold Graphite 1 2DET 016 000 KA Crucible 1 2 2DET 016 000 KB 1 kg gold Graphite Crucible 1 3 2DET 016 000 KC
22. t there is not thermocouple mounted Thermo regulator is switched OFF see Fig B7 and operator have to watch crucible temperature Note When thermo regulator is switched OFF the parameter TEM PERATURE is invisible on the 7 segment LED display SECTION CITUNING AND TROUBLESHOOTING C1 LOAD TUNING GUIDE Because of fixed tank circuit and load graphite crucible device is factory tuned and doesn t need additional load tuning C2 ALARMS FAULTS AND WARNINGS For every ERROR which appears during normal working of the device is valid flowchart shown on Fig C1 ERROR CONDITION STOP Button Main Menu Figure C1 ERROR Menu Flowchart Table Alarms and Fault Messages Version 1 2 26 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 T Fault Description Condition Cause Advice Check resonant loop Tuning Fault Primary V amp lout Can t find resonant load coil tank Erl Phase Fault frequent capacitors Transformer taps P y Possible inverter board Part Number M OD 016 210 failure Output current Possible FET IGBT failure in the 2 Current Fault Iprimary gt exceeds the limit Power supply Contact our Service department Check resonant loop values F lt Fmin or gt tank capacitors or control Er3 Frequency Fault the pre programmed Fmax board Check load coil fo
23. tput matching transformer with fixed transformer ratio air cooled tank capacitor assembly output terminals for mounting the coil and induction coil B2 2 HEAT STATION SPECIFICATIONS Table B4 Heat Station Specifications Table ELECTRO M ECHANICAL SPECIFICATIONS RATING DESCRIPTION SPECIFICATIONS CONDITION UPT 016 500 UPT 016 510 UPT 016 520 Minimum required Cooling Water cooled 2 LPM 0 5GPM flow rate Max Primary Current RM S lona 13 RMS Output Frequency Range 30 50 kHz Output Volts RM S Vomax 250 Output Transformer Ratio 21 3 21 3 18 3 Fixed Tank Capacitor capacitance 1 2 uF B3 CONTROLS AND OPERATION B3 1 CONTROL PANEL OVERVIEW The unit is digitally controlled through a control panel located on the front panel of device The control panel utilizes the latest microprocessor technology The control panels are designed to display vital parameters and alpha numeric messages providing intuitive and informative visual feedback The users can also navigate through easy to use service diagnostics and setup menus Version 1 2 17 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 016 500 510 520 00 B3 2 CONTROLS AND INDICATORS The control panel has the following controls and indicators POWER TIME min TEMP C A SELECT Figure B4 UPT 016 500 510 520 Control Panel Layout and Controls Version 1 2 18 www ultraflex
24. ure operator s safety db PROTECTIVE EARTHING CONDUCTOR TERM INAL This symbol indicates the point on the product to which the protective grounding conductor must be attached EARTH GROUND TERMINAL This symbol is used to indicate a point which is connected to the PROTECTIVE EARTHING TERM INAL The component installer assembler must ensure that this point is IK connected to the PROTECTIVE EARTHING TERM INAL CHASSIS TERMINAL This symbol indicates frame chassis connection which is supplied as a point of convenience for performance purposes This is not to be confused with the protective grounding point and may not be used in place of it Version 1 2 5 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 A1 2 3 SAFETY AND PRECAUTION SYMBOLS USED IN THIS MANUAL A WARNING symbol alerts you to a hazard that may result in equipment damage personal injury or death Carefully read the instructions provided WARNING and follow all safety precautions 1 A CAUTION symbol alerts you that the system may not operate as expected if instructions are not followed Version 1 2 6 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 UPT 016 500 510 520 00 A2 INSTALLATION AND START UP A2 1 INSTALLATION PROCEDURE The installation procedure consists of the following steps e Unpacking the equipment e Selecting the site where the equipment will be used e Connecting the Heat Station if remot
25. xk1ixixkcin xxi nbn Rx XE XE GR c Rr 17 B3 CONTROLS AND OPERATION 55555555522 2 29 17 B3 1 CONTROL PANEL OVERVIEW 5 2 2515 XRXR TEX EXE XE X EXER DE CER RE D X RETE AE KR 17 B3 2 CONTROLS AND INDICATORS ixciisixkx S nbn x KR 18 B3 3 REGULATION MODES AND SYSTEM STATUSES nnns 19 B3 4 MENUS AND NAVIGATION icu RS kx UK XE ARR E GR EU DRE ER ERG 20 B3 4 1 Menu Navigation eene nnns 20 83 4 2 Heat ON Menu 21 B3 4 3 SYSTEM MENU 22 B3 4 4 EXTENDED MENU 24 B3 5 inet E bx EXER bx X n X ER EX C EXER 26 SECTION C TUNING AND TROUBLESHOOTING nnne 26 Version 1 2 2 www ultraflexpower com UltraFlex EasyM elt 0 5 1 2 mM UPT 016 500 510 520 00 Cl 26 2 ALARMS
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