USER MANUAL - Ultraflex Power Technologies
Contents
1. o0128m0060 el h H m 5 jesja BB Bite z INDUCTOR HEAD Z sfa D a Z CONNECTOR P006 S000 aa w FOOTSWITCH KJ E Seo Ei EA CONNECTOR 7 ee SoS w A Z aga 240 9 449 Fig 2 Mechanical Outline Drawing All dimensions stated as follows mm inch 4 4 ENCLOSURE The enclosure has been designed with NEMA 2 and IP 21 standards in mind 4 5 FEATURES 4 5 1 CONTROL Control of the EasyClub Power Supply is done via a local panel integrated in the unit enclosure 4 wire bus secures the power supply of the panel as well as the RS 485 connectivity The panel has user friendly interface with 3 digit LED display and membrane keypad based on a digital state of the art microprocessor technology Individual status LED s are placed for indicating the mode of operation On board audible alarm helps easier detecting of fault and unstable operating conditions A simple multifunction 5 button membrane keypad secures easy programming in real time mode as well as retrieving user preset programs Remote control is also available through a supplied footswitch For more de2. 5 1 INSTALLATION PROCEDURE 5 2 UNPACKING AND INSPECTION 5 4 COOLING 5 5 A C INPUT CONNECTION SECTION 6 OPERATION 6 1 CONTROL PANEL OVERVIEW 6 1 1 MENU 6 1 3 STARTING THE SYSTEM 6 2 ALARMS FAULTS AND WARNINGS 6 2 1 PHASE FAULT 6 2 2 CURRENT FAULT 6 2 3 FREQUENCY FAULT 6 2 4 TEMPERATURE FAULT 6 2 5 AUTO TUNE FAILED 6 2 6 COMMUNICATION FAULT 6 2 7 INDUCTOR HEAD MISSING 6 2 8 POWER OVERLOAD 6 2 9 POWER SUPPLY FAULT 5 1 1 INSTALLATION OPERATION AND SERVICE PRECAUTIONS 5 5 5 6 6 SECTION 3 MANUFACTURER INFORMATION 7 7 7 7 7 8 8 8 8 8 8 10 10 10 5 3 SELECTING THE POWER SUPPLY SITE 10 10 10 12 12 12 6 1 2 HOW DOES IT WORK AND WHAT THE USER SHOULD KNOW 14 14 16 16 16 16 16 16 16 17 17 17 18 SECTION 7 MAINTENANCE 7 1 SCHEDULING 7 2 PERSONNEL 7 3 INSPECTION AND MAINTENANCE PROCEDURE 7 3 1 DAILY AND WEEKLY INSPECTION 18 18 7 3 2 MONTHLY INSPECTION 18 SECTION 8 SERVICE 8 1 GENERAL 8 2 SERVICE CONTACT INFORMATION 8 3 SPARE PARTS LIST 8 4 FUSE REPLACEMENT 19 19 19 19 19 SECTION 1 SAFETY INSTRUCTIONS 1 1 INSTALLATION OPERATION AND SERVICE PRECAUTIONS 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
3. facility electrical power service are customer furnished Requesting UPT field engineering assistance before customer furnished provisions are installed at the equipment site could delay equipment installation and cause unnecessary expense 5 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 UPT representative WARNING Inspect equipment before installing Damaged equipment may result in improper operation and create a hazardous condition resulting in personal injury or death The carrier is responsible for all damage caused in shipment including concealed damage 5 3 SELECTING THE POWER SUPPLY SITE Consider the following when choosing a location for the Power Supply 1 Make sure the unit is installed in a debris free zone 2 The Power Supply has to be connected to a power source 3 The Power Supply has to be in a location to allow an attached inductor head to reach the workplace 4 Make sure the unitis easily accessible by the operator 5 The Power Supply has to be seated on a mechanically secure surface 5 4 COOLING The power transistors and rectifiers in the EasyClub Power Module are maintained within their safe operating temperature range by means of f
4. heated parts of the golf club due to burn injury hazard When using the device be aware that the head and shaft are becoming hot and clamps or some additional gear might be needed in order to pull the club head off 6 1 3 STARTING THE SYSTEM NOTE Before proceeding complete all the required electrical connections 1 Attach the inductor head cable to the Power Supply using the 10 pin connector located on the front side of the unit 14 2 Make sure the Power supply is properly wired and that power to the unit is available 3 Turn the ON OFF switch on the back of the Power Supply to the ON or 1 position to turn it on As mentioned in 6 1 1 After turning the device ON it displays the software version number and enters in power setting mode See user menu structure Fig 4b Set the timer and power output according the club hosel size and the heat amount you want to reach Take the inductor head and position it over the hosel so that it covers the place that has to be heated Fig 5 The deeper the hosel gets into the inductor gap the better it s heated Fig 5 Inductor head alignment With the timer and power output already set EasyClub is ready to be started by pressing the footswitch or the front panel s start button The HEAT ON LED is lit and the timer counts down to zero after which the unit stops and HEAT ON LED goes off If the power is set for 100 or less it may be immediately restarted The minimum HEAT ON t
5. is a loss of communications between these two microprocessors An unplugged due to a mechanical shock internal cable broken wire or weak contact might be the reason for such a fault If the error occurs frequently or the unit fails to start at all contact UPT Service Department 16 6 2 7 INDUCTOR HEAD MISSING The message above indicates that the inductor head is disconnected from the power supply Check for loose connection between them and then restart If the error keeps occurring unplug the unit off the mains socket and inspect connector for traces of dirt or other obstacles that might prevent electrical contact If this doesn t help contact UPT Service Department 6 2 8 POWER OVERLOAD This message is shown when the output voltage reaches unsafe limit because the unit got overloaded Use this device only for golf club repairing or assembly If this error occurs while no load is present or at normal loading conditions contact UPT Service Department 6 2 9 POWER SUPPLY FAULT This message will be displayed when the PFC module fails or when a general fault in the Power Supply occurs Turn the unit off for about 30 seconds and then try turning it on after making an inspection of cables connections and sealing head state If the error persists contact UPT Service Department 17 SECTION 7 MAINTENANCE 7 1 SCHEDULING The UPT Power Supply is designed for continuous service and minimum maintenance requirements The frequen
6. unit 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 Par 8 2 for Service Contact Information Please have the following information about your unit available upon calling Unit Serial and Revision Number See label in Section 4 for these numbers identification Line Voltage and frequency Date of Delivery Detailed description of the problem encountered Detailed description of the actions taken Approximate time in service ouahWN If our technical staff is unable to help you over the phone then a return authorization number RA will be issued for you With this number enclosed in you return package you can ship the unit back for repair See Par 8 3 for Service Shipping Information Note No unit should be sent back for service without valid RA 8 2 SERVICE CONTACT INFORMATION For technical service questions please call 631 467 6814 You may also fax your questions or request at 631 980 4065 Note Please include you contact information so that you can be easily reached if necessary 8 3 SPARE PARTS LIST O Recommended spare parts for this unit are listed in table 3 Item Ultraflex PN Table 3 Spare Parts List UPT Corporation maintains a stock of replacement parts that are available upon request Contact UPT Corporation for further information on o
7. EasyClub USER MANUAL Induction Heating System For Manufacture and Repair of Golf Clubs Documen t No 9USR 745 110 00 Rev A01 IMPORTANT NOTES 1 This manual is valid for the following Model and the associated Revision number s MODEL NO EC 1 2 180A PFC REV NO A00 2 A Change Page may be included at the end of the manual All applicable changes are documented with reference to the equipment Revision and Serial number Before using this Instruction Manual check your equipment nameplate to identify your Model and Revision number If in doubt contact your nearest UPT Representative 3 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 4 Data subject to change without notice PREFACE YOU AND NOT THIS MANUAL ARE RESPONSIBLE FOR ALL SAFETY PRECAUTIONS Please contact the UPT Service Department before servicing any UPT equipment 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 and assumes no responsibility for any errors that may occur in this manual A Dan
8. btaining replacement parts 8 4 FUSE REPLACEMENT There are two fuses one for each line on the PFC EasyClub Power Supply They are located on the backside of the unit in plastic screwable holders Power down and unplug the unit before replacing the fuse Failure to do so will create a hazardous condition that may result in equipment damage personal injury or death Unscrew the plastic holder with flat screwdriver to gain access to the fuse Note1 Replace a burnt fuse only with the same type of fuse It is recommended that a factory certified fuse is used for replacement For fuse ordering information please see Par 6 4 Note 2 Do not overrate the fuse That is fire hazardous and may cause personal injury or death Make sure the fuse you are installing is rated 20A 250V Put a new fuse in the fuse holder and screw it back to the unit Secure the fuse screw by applying adequate screw torque Loose fuse screw may cause local overheating unit damage or fire If the fuse fails second time immediately or short after been replaced please contact the factory prior taking any other actions 20
9. cy of any maintenance program is a function of environment degree of equipment use and product experience 7 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 7 3 INSPECTION AND MAINTENANCE PROCEDURE Note Always follow approved lockout 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 7 3 1 DAILY AND 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 7 3 2 MONTHLY INSPECTION Perform the following on a monthly basis 1 Ensure all wiring connections are secure Visually inspect for any wear on cabling 2 Verify that none of the enclosure hardware has become loose 3 Remove any build up debris that may occur around the fan inlet using a cloth or a vacuum cleaner Use of compressed air is not recommended 4 Wipe the Control Panel with a damp cloth to remove any dirt prints or smudges 5 Wipe the enclosure down with a damp cloth or using stainless steel cleaner if desired SECTION 8 SERVICE 8 1 GENERAL There are no user serviceable parts inside the EasyClub
10. ec The use of max load 1 00 930W Up Down buttons Enter in System at this point alters the cycle duration Menu 13 Enter in System Menu LP p Control panel board Select Zz revision is 1 4 ee Control board lt Select ae revision is 5 1 FE 0 tow Q 3 ci CT oD tob Q Stop Sl 001 eee 1 Fa rc EErs A Up down Done Y y Le SP in IR E nd Up amp Down Tune Phase Up Down Th vi lag OL FR Frequency sweep procedure SP Power control input In Internal Out External not implemented End Exit from system menu Exit trom System Menu Fig 4b System menu structure 6 1 2 HOW DOES IT WORK AND WHAT THE USER SHOULD KNOW The device described in this manual is intended for production and repair of golf clubs in industrial as well as in small workshop environment The device works by applying alternating magnetic field to the hosel The magnetic field induces electric current inside the material which has certain resistance therefore the area exposed to the inductor head heats up After performing all the installation steps in the manual Ch 5 you are ready to work with the EasyClub Despite that the device is quite easy to operate the operator should at all times abide by the precautions and safety measures specified in this document Avoid contact with
11. econds At this point the unit might be started with all the parameters set Pressing the select button when in Heat On mode toggles display of both the parameters of power and duration Holding the Select button for more than 3 seconds brings the user to the system menu Fig 4b The system menu features that could be of use to the EasyClub operator are the Control Panel CP and Control Board CB version check menus There the system software versions info could be obtained which is useful when contacting UPT Service Department When in system menu the user may toggle between the items using the Up Down buttons Selecting and Exiting an item is done by pressing the Select button The user may exit the system menu by toggling to the End item and then pressing Select to confirm going back to the user menu Fig 4a User Menu structure Power ON A brief version p a report appears i oe after powering er on HEAT ON A LARM V TIME PO t e i Wait 2Sec E The use of a 4 Up Down buttons at this point alters wait 2 sec the power output E a HEAT O N ALARA i TIME POWER oP ALARM TIME POEs TI Start Stop I Select S y t ri p Time LED blink peat on ALARM Tint POWER J aa ALARM ra rote HEAT ON ALARM nE EA a ml bagStart Stoppe Z Up Down Lal I lt oll ee bes om Coe LED display Load in Hold Select for 3s
12. gerous voltages may be present in equipment surrounding and or connected to the EasyClub 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 the EasyClub and are familiar with its technology should be permitted to operate the system Failure to comply will void the warranty 2 Always have the Power Supply completely powered off and locked out before performing any service inspection or maintenance 3 Even with the Power Supply off live voltages still exist within the case Always power off and lock out the external power source to ensure no one can accidentally energize it 4 Ensure that all external wiring conforms to applicable codes Obey all warnings and use good common sense TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS 1 2 GROUNDING 1 3 ELECTRICAL SHOCK HAZARDS SECTION 2 INTRODUCTION 2 1 MANUAL ORGANIZATION 3 1 MANUFACTURING AND SERVICE SECTION 4 DESCRIPTION 4 1 OVERVIEW 4 2 SPECIFICATIONS 4 3 MECHANICAL SPECIFICATIONS 4 4 ENCLOSURE 4 5 FEATURES 4 5 1 CONTROL 4 5 2 PROTECTION 4 6 ACCESSORIES SECTION 5 INSTALLATION
13. ime is 0 2sec The output power can be set between the limits of 10 and 120 If the power is set between 100 and 120 the unit will automatically turn itself off in 5 seconds It will not allow to be restarted for another 5 seconds The time can be set for up to 5 0 sec As the set power output raises the pause duration needed between HEAT ON cycles increases leaving the unit to cool down Example for 120 power output and time 5 0 sec after one HEAT ON cycle there must be at least a 5 0 sec pause while for 110 power output and ON time of 5 sec the power supply must rest for at least 2 5 sec 15 6 2 ALARMS FAULTS AND WARNINGS The following are possible alarms faults and warnings that the customer may encounter 6 2 1 PHASE FAULT The primary current and voltage of the Power Supply are set in phase at the factory This subjects the semiconductor devices to the least amount of stress and reduces heat build up and extends the life of the devices This fault results when the current and voltage fall out of phase enough to possibly cause damage to the devices Continued occurrence of this fault could be an indication of Power Supply failure Contact UPT Service Department 6 2 2 CURRENT FAULT As a safety feature the current that runs through the main output circuitry supplying energy to the inductor head is monitored If that current exceeds a preset limit a current fault condition will occur This fault can be i
14. ndicative of a bad semi conductor device or a possible short in the wiring Contact UPT Service Department 6 2 3 FREQUENCY FAULT The Power Supply is programmed to run within a certain frequency range When the unit attempts to run outside the proper frequency range a frequency fault is realized A couple of reasons for this could be a drastic change in the inductance of the attached coil or possibly a capacitor that has gone bad Contact UPT Service Department 6 2 4 TEMPERATURE FAULT Making use of the temperature sensor within the MOSFET device and some external circuitry should the MOSFET device get too hot the unit will stop running and produce this fault Allow the unit to cool before trying to run it again If the fault keeps occurring make sure the fan is working properly and that none of the vents allowing air to flow through the unit are blocked If everything checks out well contact UPT Service Department 6 2 5 AUTO TUNE FAILED This message is displayed if the unit fails in automatic recognition of inductor head Please turn the unit off wait for few seconds until all the panel lights go off and then reconnect the inductor head Turn the unit on and try running it again If there is no positive result contact UPT Service Department 6 2 6 COMMUNICATION FAULT The Control Panel and the Control Board inside the unit have microprocessors which need to communicate with each other to work properly This fault occurs if there
15. nection 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 The energy unit can operate on an input voltage of 95 245 VAC 11 SECTION 6 OPERATION 6 1 CONTROL PANEL OVERVIEW The main design objective of the Control Panel is easy access to all the operational and setting functions of the EasyClub power supply as well as displaying device state data to the user in ergonomic manner The panel is situated on the upper front side of the power supply case It has five control buttons indicator LED s and a 3 digit LED display They are situated as follows TIME POWER SEC A HEAT ON v START SELECT Club Fig 3 Control Panel Layout 6 1 1 MENU The menu structure is simple but very useful as well It s structure is shown in a flowchart Fig 4a amp 4b After powering the device on the control panel software revision is displayed for a period of 2 seconds See user menu structure Fig 4b Then the unit enters in power setting mode which allows setting the power output by pressing the Up Down buttons Confirmation of the setting is done by pressing the Select button Then the duration of the Heat On cycle might be set Up Down buttons are altering cycle duration in s
16. orced cooling by 120x120mm fan For this reason the fan inlet 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 immediately surrounding the Unit does not rise above the limit specified 98 F 37 deg C Periodic cleaning of the Unit exterior is recommended 5 5 A C INPUT CONNECTION The EasyClub connects to the power network through 8 ft NEMA 5 15 power cord supplied If you are using this equipment in a country other than USA please supply proper power cord compatible with your power network outlet A list of available power cords is shown in Table 2 Note If you supply a cable cord on your own please make sure it is rated 15A and above The unit has a built in fuse protection on each line rated at 20A With its allowable 95 245 VAC input it could see a maximum current of 13A a c It is highly recommended that the unit is connected to a separate protected power branch on the in house power network 16A fuse or circuit breaker on that power branch is a good choice since it will trip before and instead of the internal protection A mechanical 30 A switch is also recommended within the operator s range and vision and possibly closer to the Power Supply See Fig 2 for details To Power Plant Circuit Breaker Cabinet Mechanical Switch Energy Unit Power Outlet Power Cord ft Fig 2 Power Line Con
17. s the purpose and organization of this manual Contains information about the manufacturer and its sales and service representatives Specifies electrically and mechanically the system Provides installation procedures Explains how to set different parameters and how to use the inductor head This section also gives explanation for the whole Provides instructions for periodic inspection and maintenance Explains the service procedures and provides manufacturer contact information A WARNING symbol alerts you to a hazard that may result in equipment damage personal injury or death Carefully read the instructions provided WARNING and follow all safety precautions A CAUTION symbol alerts you that the system may not operate as expected if instructions are not followed Extra user information is provided in the text following this sign SECTION 3 MANUFACTURER INFORMATION 3 1 MANUFACTURING AND SERVICE ULTRAFLEX POWER TECHNOLOGIES 154 1 Remington Blvd Ronkonkoma NY 11779 Tel 631 467 6814 Fax 631 980 4065 SECTION 4 DESCRIPTION 4 1 OVERVIEW The UPT EasyClub is a unit designed to work in conjunction with inductor head designed exclusively for it The unit is digitally controlled through a membrane keypad located on the front panel The Power Supply is enclosed in a compact case ON OFF switch is installed on the back side of the enclosure to power up and down the unit Waterproof connectors are interfacing the po
18. tails see section 4 6 Accessories 4 5 2 PROTECTION 1 Overpower protection Tracks output power activated if the output goes out of tolerance 2 Over current protection Tracks output current activated if the output goes out of tolerance 3 Input Over current protection Tracks input current activated if the input goes out of tolerance 4 Over temperature Activated when the internal temperature exceeds a safe operating threshold 4 6 ACCESSORIES The following accessories are available for system enhancement and customization ACCESSORY Ultraflex P N Foot Switch 1ACC 737 500 00 Power Cord US style NEMA 5 15 8ft 4KAB 000 018 00 Inductor Head 1ACC 745 100 00 Table 2 Accessories SECTION 5 INSTALLATION 5 1 INSTALLATION PROCEDURE The installation procedure consists of the following steps Unpacking the equipment Selecting the site where the equipment will be used Connecting the inductor head to the Power Supply Connecting the foot switch if necessary Completing the power and Ground Earth connections AUN 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 that is available to supervise the installation of the equipment If installation service is required contact the UPT Technical Service Department for additional information Provisions for
19. wer supply with the inductor head and the foot switch The power level is automatically adjusted depending on the actual value of the load The unit is equipped with Power Factor Corrected PFC front end module to meet the CE mark thus optimizing the line current utilization and reducing power bill cost Note 1 A tool is required to gain access to the Power Supply This is to prevent accidental exposure to the internal high voltages 2 See section ACCESSORIES for optional equipment 4 2 SPECIFICATIONS The PFC EasyClub system s electrical and mechanical specifications are listed in Table 1 MAIN FEATURES Size 7 wide x 12 high x 9 5 deep 180 x 300 x 240 mm Weight 14 Ib 6 4 kg Max operating ambient temperature 97 F 36 C Universal Input line voltage 110 230 Volts AC 50 60 Hz single phase Max output power rating 1 2 kW Nominal output frequency 50 200 kHz Thermal protection Built in thermal protection with automatic fan control CONTROL PANEL AND USER FEATURES Displays LED s Heat On Alarm Time and Power status lights 3digit 7segment LED 0 2 9 9 sec 0 1sec step 10 60 sec 1 sec step Power control 10 120 PWM 1 step OTHER FEATURES Power monitoring and automatic power limiting capabilit Dry flexible lead connects the power supply to the inductor head Table 1 Specifications 4 3 MECHANICAL SPECIFICATIONS ON OFF SWITCH
20. with hazardous internal voltages is provided There are no operator serviceable parts or adjustments within the product enclosure 1 2 GROUNDING This product is a Class 1 device which utilizes protective earthing to ensure operator s safety 1 3 ELECTRICAL SHOCK HAZARDS This product outputs hazardous voltage and energy levels as a function of normal operation Operators must be trained in its use and exercise caution as well as common sense during use to prevent accidental shock levels as high as 500V D C may exist in the course of normal or single fault conditions A This symbol appears adjacent to any external terminals at which hazardous voltage Source power must be removed from the product prior to performing any servicing SECTION 2 INTRODUCTION 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 2 1 MANUAL ORGANIZATION Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 The manual also uses WARNING and CAUTION Safety Instructions Introduction Manufacturer Information Description Installation Operation Maintenance Service Discusses hazards and safety precautions Identifie
Download Pdf Manuals
Related Search