SP-15A Portable High Frequency Induction Heating Unit

Operation

Manual

MTI Corporation
860 South 19th Street, Richmond, CA 94804, USA Tel: 510-525-3070 fax: 510-525-4705 Email: info@mtixtl.com Web: www.mtixtl.com

Content 1. Introduction: .......................................................................................................................... 3

1.1 Applications: ............................................................................................................................................3 1.2 Features of SP-15 series:........................................................................................................................3

2. Specification .......................................................................................................................... 3 3. Front Panel ............................................................................................................................ 4

3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 5.1 5.2 5.3 5.4 6.1 6.2 6.3 6.4 6.5 6.6 6.7 LED....................................................................................................................................................5 Button.................................................................................................................................................5 Knob...................................................................................................................................................6 Display ...............................................................................................................................................6 Time preset.........................................................................................................................................6 Remote control socket........................................................................................................................6 Switch ................................................................................................................................................6 Main Power switch ............................................................................................................................7 Control power switch.........................................................................................................................7 Grounding ..........................................................................................................................................7 Cooling water......................................................................................................................................7 Grounding ..........................................................................................................................................9 Install the induction coil.....................................................................................................................9 Connection of remote control switch...............................................................................................10 Check before use................................................................................................................................10 To adjust the function on front panel.................................................................................................10 Turn on the main power switch .........................................................................................................10 Turn on the control power switch ......................................................................................................10 To operate and heat at auto status (with timer on) .........................................................................10 To operate and heat at manual status..............................................................................................11 To turn off ..........................................................................................................................................11

4. Back Panel ............................................................................................................................ 7

5. Installation ............................................................................................................................. 7

6. Operation ............................................................................................................................. 10

7. Troubleshooting12 Design and manufacture of inductorium ................................................................................. 13 Product Details ........................................................................................................................ 15

Notice Before Using

1. Make sure to use soft and pure water, and its temperature should be lower than 40 C (104 F). 2. The induction coil is very important to heating efficiency, so please consult us if you have any questions of designing your own induction coil.
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1. Introduction:
SP-15A is a kind of high frequency heating equipment, which features the latest inverting technology so as to make itself light and convenient.

1.1 Applications: 1.1.1 Soldering of diamond impregnated cutting and grinding tools which includes: a. b. c. d. 1.1.2 1.1.3 1.1.4 segmented diamond saw blade from 250-2500mm diameter thin-wall diamond impregnated bit diamond impregnated grinding disk diamond impregnated tube, etc.

Soldering or brazing of cutting and drilling tools, etc. Heating treatment of metal parts Melting metal materials

1.2 Features of SP-15 series: a. Quite light and portable b. High heating speed, like segmented diamond cutting disk of 1600 diameter less than 10 seconds for soldering in one segment c. High duty cycleless than 80% even in summer time, to work continuously d. Easy installation f. Power saved g. Flexible coil with great function

2. Specification
Model Input voltage Input voltage range Maximum oscillate power Duty cycle Output oscillate frequency Heat oscillate current SP-15A 220V single phase 180-245V 15KVA 80% 30-100KHz 200-600A

Retain oscillate current Heating time Retain time Cooling time Net weight SIZE Cooling water pressure Cooling water temp. <40o C (104oF)

200-600A 199 seconds 199 seconds 199 seconds 18Kg 194x400x350 >0.2MPa Cooling water flux > 2L/min

3. Front Panel

3.1

LED:

3.1.1

Power LED: When the input power is connected and the both switches on back panel and on front panel have been put on, this red LED will be on to indicate the control power is OK.

3.1.2 3.1.3

Operating LED This green LED will flash accompanying with pulsed buzzing when heating process is ongoing. Over voltage LED 220V single phase is required for this machine, and the voltage range is from 180v, to 245v.when the input voltage is higher than 245v, this red over voltage LED will be on accompanying with continuous buzzing, and machine stops working automatically. This LED will be off as well as buzzing when the input voltage is lower than 245V.

3.1.4

Over current LED When this red LED turns on accompanying with continuous buzzing, at the same time, the machine will stop working automatically, this may caused by follows: a.
b. c. d.

Interfering signals Equipment failure Short circuit of the induction coil caused by contacting with the work piece. Contact between induction coil power (adjust by power adjusting knob) and then adjust the power to your desire one. If the alarm keeps going, please contact us at info@mtixtl.com.

Solution: shut off the power; eliminate the points referred above, if the alarm vanishes, restart the machine with a lesser

3.1.5

Water lacking LED Inside the machine, there is a water pressure meter to measure the cooling water which is used for cooling down the coil and some other parts. If the cooling water pressure is lower than rated value, this red lack of water LED will turn on accompanying with continuous buzzing, and the machine will stop working automatically. The LED and the buzzing will go off when the cooling water pressure is large enough for use.

3.1.6 3.1.7 3.1.8

Heat LED Either at auto or manual status, this red LED shines when the heating process is ongoing. Retain LED Only at auto status, this red LED will shine when retaining process is ongoing. Cool LED Only at auto status, this green LED shines to indicate that heating operation has been finished and cooling process is ongoing.

3.2

Button

3.2.1

Start button

Press this button to start the induction heating process both at auto and manual status, but if foot switch or remote control switch with normal open and normal close contact, is connected by remote socket to machine, the start button will be invalid, instead the foot switch or other remote control switch can be used to start the operation of the machine. 3.2.2 3.2.3 Stop button Press to stop any operation of this machine Period Convert button This button is only valid at auto status. At auto status, the three periods of heating, retaining and cooling will be processed automatically according to the time adjusted, but any push of the period convert button will convert the period to the next at once.

3.3

Knob

3.3.1 3.1.2

Heating Power Adjust Knob This knob can be turned to adjust the heating power of the machine to control the heating speed. Retaining Power Adjust Knob This knob is only valid at auto status to adjust the retaining power of the machine.

3.4

Display

3.4.1 3.4.2

Current display This display will show the output current of the machine. Time display At manual status, this time display will show out the heating time; at auto status, this time display will show out the heating time, retaining time and cooling time correspondingly.

3.5

Time preset To set the heating time, retaining time and cooling time from 1~99 seconds orderly.

3.6

Remote control socket By this socket, foot control switch or remote control box or other remote control can be connected to control the start and stop of the machine.

3.7 3.7.1 3.7.2

Switch Control Power Switch This switch functions to turn on or off the control power of the heating machine. Auto/manual select switch

This switch selects the status of time control function. Once start the heating in auto status, the machine will process automatically according to the preset heating power, retaining power, heating time, retaining time and cooling time. When select manual status, the time controller will be invalid, and the operator will start or stop the heating process manually.

4. Back Panel
4.1 Main Power switch To switch on or off the power supply of the machine. 4.2 Control power switch 1A fuse protects the control circuit of the machine. 4.3 Grounding Proper grounding of the machine should always be done to ensure the safety, it is suggested that 2.5MM2 Copper wire be used for grounding.

5. Installation
5.1 5.1.1 Cooling water Standard of water Proper Cooling water is very important for the effective use of induction heating machine, so pure and clean water is required, but if the water property is not satisfied, or the water resistance is very small, there will be a great danger caused by electricity, so, please follow the standard: Flux of the cooling water: 6L/min Cooling water pressure: 0.2 Mpa Temperature of the Cooling water: <40o C Cooling water purity desire: PH: 7.0~9.0 Chloride composition<20ppm Nitrate composition <10PPm Calcium carbonation<250PPm Resistivity (Under 25oC)>2500ohm/cm Total impurity composition<250PPm Non depositing temperature of impurities: <57 o C 5.1.2 Cooling water suggested Following water can all be used as cooling water. But priority is from left to right:

Distilled waterSoft waterPure waterFiltrated water supply 5.1.3 5.1.4 5.1.5 Cooling water forbidden Sea water, unstrained water from river and well. Suggested cooling water system Circulation water system together with heat exchanger or city water supply. Connection of the cooling water to the machine To connect the water in water out of the machine to the circulation cooling system according to figure below, and attention should be paid that: Front panel of the machine Back panel of the machine for water and power connecting

Water in connection

Water out connection

5.2

grounding 4mm2 copper wires should be used for proper grounding of the machine for safety of operator and personal nearby.

5.3

Install the induction coil Correct induction coil is the key to achieve satisfactory heating. Special care should be taken to install the coil to assure best electricity contact cooling. 1) Inside 50mm around the coil, ferrous material should not be used, for example, the fixture and water tube clip which are made of ferrous material, should all be put 50mm far away from the induction coil.

2)

There is one pressure meter inside the machine to test the pressure of the cooling water and to stop the operating automatically when water pressure is too low to work, while these pressure meters can not test the water pressure through the induction coil. So in order to protect the coil from water-lacking destroy, best way is to make the water connection according to figure2, using one valve to control two water in.

5.4

Connection of remote control switch Just refer to figure below to make the connection of foot switch.

Foot Switch Off 1. Stop 2. Common 3. Start 1 2 3 Foot Switch On

6. Operation
6.1 1) 2) 3) 4) 6.2 1) 2) 3) 4) 6.3 6.4 Check before use: Make sure that all the installation be finished. Make sure proper induction coil be connected Make sure there is enough water flux in every water out hose. Avoid idle load state. To adjust the function on front panel Select Auto/manual switch status. Select front panel operation foot switch operation, if front panel operation is preferred, foot switch should be taken away without connection. Adjust the heat power adjust knob and retain power adjust knob according to your target temperature. At auto status, adjust the heating time; retain time and cooling time according to your target temperature. Turn on the main power switch on the back panel of the machine. Turn on the control power switch on the front panel of the machine, then power LED on front panel is on.

6.5

To operate and heat at auto status (with timer on) For machines with timer, push the start button or the foot switch to start the heating, and then, the timing procedure will go automatically from heating to retaining according to the time preset. When times out, the machine will stop automatically.

Points should be mentioned that: 1) To push the stop button on front panel can stop the operation of the machine at any time. 2) If start button or foot switch is pressed when operation is still ongoing, the timing may go wrong, 3) Start button on front panel will be invalid when foot switch is used.

6.6

To operate and heat at manual status Push start button on the front panel or hold the foot switch to start the machine, then the operate LED begins to flash, the time display counts the accrual heating time with heat LED shining and the digital meter shows the heating current or heating power which is preset by the heat power adjust knob; either stop button on front panel or the foot switch releasing will stop the heating (start button on front panel will be invalid when foot switch is used).

6.7

To turn off 1) 2) 3) 4) Turn off the control power switch on the front panel. Turn off the main power switch on the hack panel of main part of the machine. Turn off the power switch of input power. Turn off the water valve.

7. Trouble Shooting
7.1 Attention for trouble shooting 1) The customer should be advised to have professional technician do the trouble shooting, or, damage may happen to both people and the machine. 2) If there is any uncertainty about the trouble shooting, please contact us at info@mtixtl.com 7.2 Ease the trouble shooting before checking 1) Take off the foot switch or other remote control, only use the button on the front panel to operate and needless to hold the button for long. 2) For the machine with timer, please change to manual state. 3) Minimize the current and power by adjust knob. 7.3 Normal phenomena for machine 1) When the load is heavy, the actual power or current may decrease or can not reach the presetting value, and the heavier the load, the more the current decreasing; The trouble shooting below is a reference for the customer:

NO 1

Problem

No power: the power LED and the digital meter on the front panel does not light

Probable Cause 1. The main switch or the control switch is off 2. The control fuse blows 3. The main switch or the control switch is damaged. 4. Damage inside generator 1) Control transformer is damaged 2) Main power board is damaged 5. No input power 1. The induction coil is improper.

Solution Turn on all the switch

Check the fuse build in the back panel Replace new ones

Generator can not be started

2. Short circuit between coils 3. Machine: (1) Primary coil of H.F. transformer damages (2) Potentiometer on the front panel damages

Check if the output is 15v Check the DC output on the board Check the input circuit Refer to the Design and manufacture of inductorium to make a proper one Insulate the coils Check the primary coil, damage is mainly caused by bad cooling 1. Check the voltage on the 108 pin of S3, it should change from 1-5v when rotating the knob. 2. Replace the potentiometer or the whole front panel. Check the value and replace if unqualified Replace Replace Replace Check the coils and insulate them

Workpiece can not be heated or heating rate is too low but with normal display and di-di buzzing. Over-temperature LED light with continuous buzzing Over input voltage: The LED lights with continuous buzzing.

(3) Oscillating capacitance damages or at low value (4) Main control board or driving board damages (5) Power module damages (6) Feedback tester damages Short circuit between the coils

1. The temperature of the cooling water is too high or the flow rate is too low 2. Temperature sensor failure 3. The water sink is too dirty 4. Main board in bad condition 1. The input voltage is higher than 245v

Adjust the cooling system Replace Clean up or replace Replace or repair Measure the input voltage and make sure it is in the range of 180-245v

2. Potentiometer presetting on the main board is not correct 3. Main control board damages

Reset the value for over input voltage control by adjusting the potentiometer Replace

Design of Inductorium
1. Usually, the shape of inductorium depends on heating part of work piece with the manufacturing principle as: copper tube of induction part shall be parallel or equal in distance to the heating face of work piece, and current direction flows alike between adjacent coils. 2. Coil number of inductorium is generally more than 2 and less than 10. 3. The gap between inductorium and work piece shall be controlled in 1-10mm and the smaller, the better if possible. However, if too small, heating may stop when the coils becomes light red, even no heating at all. On the other hand, if too large, heating may be not ideal, even worse, no startup. So inductorium shall be trial manufactured for some work piece. In general, when work piece is heated to be red, it is better for current output indication above 1000A. 4. If no influence on operation, the shorter and thicker the eduction part of inductorium is, the better its utility is (not more than 40mm). 5. Coiling of inductorium head a. Choose pure copper tube with external diameter 4-8mm (best for 1mm thickness). b. Anneal copper tube first. c. According to the designed shape of inductorium, bend and beat it into shape with wood hammer, slowly beat at the bent part by applying appropriate force so as to avoid generating dead bend, which would block water. Do not pinch it into burr by pincers to avoid striking fire at the end. When finishing the bend, flare two copper outlets and check whether it is ventilated. d. In order to avoid striking fire between the work pieces and coils; please wrap the coils with refractory insulating materials (such as silica gel tube or glass tape). 6. Manufacturing of two copper tubes educed a. Choose pure copper tube with external diameter 4-8mm, use square copper tube for high power. (thickness 1-1.5mm). b. Intercept proper length with one end flared and another burnished. No need flaring but bending for high power machine. Notes: do not make dead bent to block water flow. 7. Burnish the part of inductorium and two copper tubes educed which are to be welded together, then do the soldering (suggest: at least use 150W brand iron). Pay attention to the welding quality, like smooth soldered dot without air pocket. Never block up tube outlet. 8. Illustration of inductorium

Product Details

If you have any question, please contact us at Tel: 1-510-525-3070 or Email: info@mtixtl.com, MTIs engineer will help you out in 24 hours.