GYS 061644 Powerduction Heat Controller Instruction Manual

POWERDUCTION HEAT CONTROLLER
Instruction Manual

061644 Powerduction Heat Controller

GENERAL INSTRUCTIONS

This manual contains safety and operating instructions, to be followed for your safety. Please read it carefully before using the device for the first time and keep it in a safe place for future reference. Read and understand the following safety recommendations before using or servicing the unit. Any change or servicing that is not specified in the instruction manual must not be undertaken. The manufacturer is not liable for any injury or damage caused due to non-compliance with the instructions featured in this manual . If there is any issue or uncertainty, please consult a qualified individual to operate the equipment correctly. This machine should only be used for operations comprised within the limits indicated on the machine and in the instruction manual. The operator must observe the safety precautions. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury. Any other uses not specified in this manual is forbidden, and possibly dangerous. The product is semi auto- matic and requires the presence of an operator.
This unit can be used by children aged 8 or over and by people with reduced physical, sensory or mental capabilities or lack of experience or knowledge, if they are properly monitored or if instructions for using the equipment safely have been read and risks made aware of. Children must not play with the product. Cleaning and maintenance should not be performed by an unsupervised child.
Do not use the charger if the mains cable or plug is damaged.
Do not cover the device.
People wearing pacemakers are advised to not come close to the machine. Risk of disruption of pacemaker operations when close to the machine.
Consult a doctor before getting close to induction heaters.

Warning ! Very hot surface. Risk of burns.

• **** The parts and pieces that have just been heated are hot and may cause burns when manipulated.
• Do not touch any hot parts with your hands.
• Wait for the parts and pieces to cool down before handling them.
• Check that jewellery (such as wedding rings) or other metal pieces do not get close to the induction heating machine or the inductor when switched on.
• Remove any jewellery or any metal object from yourself before using this machine
• People with metal implants should not use this machine.
• In case of burns, rinse with water abundantly and see a medical doctor as soon as possible.

Connection:

• **** This machine must be connected to an earthed socket.

Maintenance:

• If the power cable is damaged, it must be replaced by the manufacturer, its after sales service or an equally qualified person to prevent danger.
• Warning! Always disconnect from the mains before performing maintenance on the device. High Voltage and Currents inside the machine.
• Remove the casing on a regular basis, to remove any excess dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Do not use solvents or any agressive cleaning products.
• Clean the device’s surfaces with a dry cloth.

Regulations:

• Device complies with europeans directives.
• The certificate of compliance is available on our website.
• EAC Conformity marking (Eurasian Economic Community).
• Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
• Equipment in conformity with Moroccan standards.
• The declaration Cم (CMIM) of conformity is available on our website (see cover page).

Waste management:

• This product should be disposed of at an appropriate recycling facility. Do not throw away in a domestic bin.
• The product’s manufacturer contributes to the recycling of its packaging by contributing to a global recycling system.
• This product should be recycled appropriately

GENERAL DESCRIPTION

The Powerduction Heat Controller is an intelligent box that acts like a thermostat on the Powerduction 110/160/220LG.
It regulates the temperature of the part to be heated between 80°C and 350°C.

POWERDUCTION CONNECTION

1. Disconnect the pedal from the Powerduction and then connect it to the Powerduction Heat Controller.
2. Connect the product cable to the front panel of the Powerduction.
3. The Powerduction Heat Controller is connected. Select an operating mode.

**OPERATION WITH 2 THERMOCOUPLES (SUPPLIED)

**

(FIG I)
Set the switch (8) to ON and press the heater enable button (9) (pedal activation).
Connect the supplied thermocouples to the side of the interface:

Thermocouples should be installed as close as possible to the area under the inductor ferrite.
It is recommended to drill the workpiece below the area to be heated with a drill bit of diameter 2 to a depth of about 1 to 2mm.
If switches (1) and (2) are in the OFF position, the Powerduction Heat Controller displays the highest measurement on the Powerduction 110/160/220LG.

OPERATION WITH A PYROMETER (ref. 064119) (FIG I)

1. Set switches (2), (7) and (8) to ON.

2. Connect a thermocouple (supplied) to a thermocouple thermometer (not supplied).

3. Connect the pyrometer to the Powerduction Heat Controller (2 connectors)
   When plugging the pyrometer, observe the connection direction of the thermocouple connector.
   The positive terminal of the connector should be towards the front of the Powerduction Heat Controller, the negative terminal towards the rear.

4. Install the pyrometer on the Powerduction 110/160/220LG lance using the adapter and nylon screws provided.

5. Install the thermocouple on the part to be heated as close as possible to the ferrite of the inductor (it is recommended to drill the part below the area to be heated with a 2 mm diameter drill to a depth of approximately 1 to 2 mm to insert the thermocouple).

Emissivity adjustment (while heating and staying in the same place on the workpiece)

1. Turn the screw of the blue potentiometer (see wiring diagram) with a flat screwdriver 2.5 until the value displayed by the thermometer is identical to the value displayed on the Powerduction 110/160/220LG (+/- 3°C).
2. Once the setting has been made, remove the thermocouple from the piece to be heated.

Adjusting the emissivity is essential for a good measurement.
By turning the potentiometer clockwise, the displayed setpoint on the Powerduction 110/160/220LG will decrease and the temperature of the part to be heated will increase.
By turning the potentiometer anticlockwise, the displayed setpoint will increase and the room temperature will decrease.
It is advisable to point the heater in the opposite direction to the pyrometer location (see photo opposite).

Connecting diagram

or to connect an external switch (which replaces the pedal)
Pyrometer| Emissivity| This potentiometer allows to modify the setting (thanks to the screw) and to refine the temperature measurement according to the emissivity of the part to be heated.
Power| this connector is used to connect the pyrometer (e.g. pyrometer – ref 064119)

Switch setting

1| sif ON cancellation of thermocouple 2 measurement| {If both are OFF, the highest  measurements is displayed.
---|---|---
2| if ON cancellation of thermocouple 1 measurement
3 et 4| offline
5| if ON activation of an OFFSET for the initial display at 100°C (button 5 has priority over all the others) (do not use for a thermocouple measurement)
6| if ON and switch 5 OFF initial display at 0 (do not use for thermocouple measurement)
7 et 8| if ON activation of the footswitch connected to the REMOTE input

OPERATION WITH PYROMETER ANALOG OUTPUT (not supplied)
Use a pyrometer sensor with an analog output directly on the product connectors (to be adapted according to the datasheet of the pyrometer used)
Example of a current measuring pyrometer

In this case, the value of the shunt R resistance on U T° must be adapted according to the setpoint and the desired accuracy (10 mV per Degree).
Correspondence table

**MANUAL MODE

**

(FIG II & III)
For an optimal use of the product, it is recommended to set the power between 30 and 50%.
To return to the «outdoor temperature control» mode:

1. Press and hold the heating enable button (9) for 5 seconds.
2. The button blinks every second and «rEG» is displayed.

The button on the lance (10) and the pneumatic pedal (11) are deactivated in this mode.
To set and then activate the heater :

1. Adjust the control setpoint: Press the adjustment buttons (14).
   The regulation setpoint varies from 80°C to 350°C (default value at 250°C) in 10°C steps. It is displayed for one second.

2. Adjust the heating power setpoint (%): hold down the «Inductor change» button (13) and press the adjustment buttons (14). The heating power setpoint ranges from 10% to 100% (default 50%). The power is updated on the bar graph.

3. Activate the heater: connect the pneumatic pedal (11) of the generator to the interface and press it.
   The minimum power light (12) flashes at 10 Hz to indicate that the power is active.

It is possible to re-adjust the heater when it is active. In this case, it is not necessary to perform step 3. The heating in progress adapts to his new instructions.
AUTOMATION MODE (FIG II)
The product can be controlled by an automaton (see pin assignment) via the external interface.
To enter the «outdoor temperature control» mode (see pin assignment below):

1. Switch on the product.
2. Wait for the end of the start-up phase 5 s.
3. Close the Start contact.
4. Wait for the OK/Secur output to close (500 ms).
5. Release the Start contact after detecting the OK/Secur.
6. Check that the OK/Secure output remains closed.

The product enters the «external control mode» and generates a melody.
The heat enable button (9) and the LED on the lance button (10) flash once per second as long as the mode is activated.
To set the temperature setpoint and heating power: perform the same operation as in manual mode.
To activate the heater :

1. Close the start switch. The product will heat until the set temperature is reached and regulated.

If the product detects a fault, then the OK/Secur output opens and the heater stops.
To acknowledge the fault, open the Start contact and press the heater enable button (9).
The product returns to «regulation» mode.

BROACHING

Function| No. of the wire| Type| Electrical settings| Values| Logic
---|---|---|---|---|---
Generator ready
OK/Secur| 3-Jan| Digital output| Type
Permissible direct current| Dry contact
5 A 30 V| Closed
Ready-to-heat generator
Opened
Generator fault
Earth| 8| Earth| Earth| Terre| Earth
Start| 10-Sep| Digital input| Residual voltage (open
circuit)
Input impedance| 15 V
3.5 kΩ| Requires the use of a dry contact: a closed contact activates the heater.
Regulation voltage U T°| 11 – /14+| Analog input| Maximum input voltage
Input impedance Accuracy| 5 V
5.4 kΩ
+/-5%| Image input of the measured
temperature.
See correspondence table
Interface power| 13-Dec| Continuous power supply| Output voltage
Output impedance| 15 V
100 Ω| .

DIAGRAM OF AUTOMATION START UP

![GYS 061644 GYS 061644 Powerduction Heat Controller - DIAGRAMHeat Controller

• DIAGRAM](https://manuals.plus/wp-content/uploads/2023/02/GYS-061644 -Powerduction-Heat-Controller-DIAGRAM.jpg)

SAFETY AND DEVICE FAILURE

• If the temperature input does not change after 5 s, the product is set to fault “E12”.
• If a thermocouple breaks, then the regulation stops because the voltage U T° exceeds the maximum voltage of 4.9 V.
• f the temperature drops significantly within a short period of time (e.g. when thermocouple probes go out of order), the heating stops and the product goes to fault “E11”.
• In order to have the most accurate control possible, the measuring point(s) must be as close as possible to the inductor.
• This is the reason for the 2 thermocouples on the external interface.
• The display shows the highest temperature measured by the sensors.

WARRANTY
The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment related failures (pollution, rust, dust).

In case of failure, return the unit to your distributor together with:
– The proof of purchase (receipt etc …)
– A description of the fault reported

GYS SAS
1, rue de la Croix des Landes
CS 54159
53941 SAINT-BERTHEVIN Cedex
FRANCE
www.gys.fr
73502_V3_18/05/2022

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