GYS 068643 Electric Induction Heater Instruction Manual

POWERDUCTION 10R
Instruction Manual

Translation of the original instructions

SAFETY 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 automatic 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 appliance if the power cord or the mains plug are damaged.
Do not cover the device.
Do not obstruct the cooling vents. Refer to the installation section before operating the machine.
Fire and explosion risks!

• Do not use the device in an explosive atmosphere.
• Keep airbags, gas cannisters or other pressurised gas containers away from the induction heating machine.

Warning, heat and flame risk.

• Do not overheat parts and adhesives.
• Be wary of fire, keep a fire extinguisher is in the vicinity..
• Do not position the machine on, or near flammable surfaces.
• Do not position the machine near flammable materials.

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.

Dangerosity of the gas fumes

• Keep the head away from the fumes, do not inhale.
• If working inside, ventilate the area or use a fume extractor to evacuate the gases and fumes.
• Induction heating of certain materials such as adhesives and flux can generate fumes and gases. Breathing these fumes and gases can be dangerous for your health. For example, heating urethane generates a gas : hydrogen cyanide, po- tentially mortal for hu-mans.
• If the ventilation is insufficent, use an approved respiratory unit.
• Read the safety data sheets (MSDS) and the manufacturer’s ins-tructions for adhesvies, flux, metals, consumables, coatings, clea-ning agents, corrosives, and paint strippers.
• Do not use the heater on parts being degreased or sprayed. The heat might react with fumes and generate highly toxic gases.
• Work in a confined area only if it’s well ventilated, or use an ap-proved repiratory/filtration unit. Make sure that a qualified per-son is around to watch over you. The fumes and gases released while heating can replace oxygen or air, causing accidents or death. Check the quality of the air you’re breathing
• Do not overheat metals, such as galvanised steel, covered with lead or cadmium, unless the coating is removed from the surface before it’s heated, that the area is well ventilated, and if needed, use an approved filtration/respiratory unit.. Foundry pieces and all metals containing such elements may generates toxic fumes if overheated.
• Check the MSDS for temperature related details.

Warning, electrical danger
Caution: Danger of optical radiation when the heated metal ele- ments reach fusion.
Warning ! Major magnetic field. People wearing active or passive implants must be informed.
No further protectective steps are required when the machine is used on its own. Further restrictions and/or protective measures may be necessary in other cases.
After maintenance, the magnetic field levels must be checked be-fore the machine is used again.
When switched on, never put the inductor near the head or vital organs.
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.
Risk of metal or adhesive projections

• Wear approved protective goggles with lateral protections, or protect the whole face with a screen.
• Wear protective clothes.
• Wear gloves.

Do not obstruct the machine’s air intake, which facilitates air circulation. Check the installation chapter before using the device.
Connection:

• This machine must be connected to an earthed socket.
• These Class A devices are not intended to be used on a residential site where the electric current is supplied by the public network, with a low voltage power supply. There may be potential diffi-culties in ensuring electromagnetic compatibility on these sites, because of the interferences, as well as radio frequencies.

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.
• Service should be performed by a qualified person.
• Warning! Always disconnect from the mains before performing maintenance on the device. High Voltage and Cur- rents 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.

DESCRIPTION

The Powerduction 10R has been designed to heat ferrous metallic elements by induction heating. Its main purpose is the unjamming of parts such as bolts or exhaust pipes.
Carry cas econtents:
Le Powerduction 10R is supplied in a carry case that contains t(see fig.1) :
– the generator and its inductor cable , 1 ,
– 3 coiled wired, diameter 18 mm / 24 mm / 30 mm 2 ,
– a flexible braided wire3 ,
– a straight rigid wire 4 .

| Spiral wire Ø18 mm 054806
---|---
Spiral wire Ø24 mm 054790
Spiral wire Ø30 mm 055469
| Flexible braided wire 054813
| Rigid straight wire 054868

**** The elements contained in this carry case are fragile. They’re to be handled with care.

MAINS POWER SUPPLY

This equipment is supplied with a 16 A CEE7/7 type plug and should only be used on an electrical installation single-phase 230 V (50 – 60 Hz) three-wire with a neutral connected to earth.

STARTING

Assembly
Choose the required tool (one of the 3 coiled wires, the braided wire or the straight wire) and fit it on the inductor. To do so, insert the two rods of the selected tool and insert them into the holes intended for this purpose, then screw the tightening wheels (fig.2). To unscrew a tightening wheel, it is possible to use a spanner/wrench size 12. Warning: never use a spanner/wrench to screw the tightening wheel as it may get damaged.
Heating activation

Press the inductor button to activate the heating. Keep pressing the button to keep the heating active.| The green LED flashes green as long as the heating is active.

Protections
The product is equipped with protections :

Thermal protection| The orange LED is lit when the product is in thermal protection. The product trigger is inactive during this time. Wait for the orange LED to go out before restarting the heating process.
---|---
Overcurrent protection| In case of overcurrent, the orange LED flashes. The product trigger becomes inactive. Restart the product to clear the fault and restart heating.
Trigger defect| On power-up, if the Powerduction detects a fault on the trigger, the orange LED lights up. Disconnect the faulty trigger and replace it. Then restart the heater.

RECOMMENDATIONS

The coiled inductor is designed for unjamming. it heats metal pieces or parts via induction to unblock and remove them easily. Circle the piece using the appropriate accessory (coiled, braided, straight), then heat the inductor, that will be used to heat the metal piece. Once the piece starts to be coloured in red, stop the heating and remove it using the right tool (clamp, spatter/wrench…) then remove it.

ACCESSORIES

** The accessories provided are consumables. These must be replaced when they are damaged.
Damaged consumables (burnt sleeves, etc.) can cause serious damage to the product.
Spirals must be made up of at least 3 turns in order not to damage the product.
In order to be able to work on parts with multiple shapes, 3 types of accessories accompany the inductor.
3 coiled wire (Ø 18, 24, 30 mm)
Standard tool, already shaped for a fast and effective operation. The coil shape enable optimises the concentration of the magnetic fields in its centre, which guarantees a powerful and effective induction heating. The glass fiber circle can electrically insulate the coils as well as the element to heat. The coil is used in the following way : position it at the centre then press the inductor’s button to start the heating.
Heating efficiency :
To achieve maximum heating power efficiency, the coil must be adapted to the workpiece.
Flexible braided wire
The braid is designed for pieces that cannot be heated with the coil (parts with a bigger diameter) :
Ex. an exhaust pipe or a wheel hub
The braid can be enrolled around the metal piece.
To obtain a better result, circle 3 times around the metal piece and make sure that the coils are bonded together. Press the inductor’s button to start the charge.
Straight rigid wire**
The straight rigid wire is designed to suit any of the user’s needs. It can be :
– adjusted to the shape of a specific part/piece.
– adjusted to a piece that is too big for the coils.
– copy the shape of an existing coil if the latter is damaged.
It works in the same way as coils and braided wire. Its shape must be adjusted to fit the metal piece’s shape and if possible, circle around the piece several time for maximum efficiency.

OPTIONAL ACCESSORIES

| 066601 Adhesive-removal inductor
---|---
| 079472 Ferrite inductor for all types of ferrous metals.

RECOMMENDATIONS

• When heating the coils for the first time, some smoke will be released.
• Avoid heating for more than 30s, the coils will heat excessively and suffer premature damages.
• It is not necessary to come in contact with the bolt to heat it.
• The coil’s protective fabric is fragile, it is glass fabric : make sure to store the coils in such a way that they do not get damaged.

The coils heat very fast. After use, is is recommended to let them cool down before storing them. Manipulate with gloves to prevent burns or itches caused by the glass fabric.
**** Do not place a finger or any limb inside or close to the coil when the machine is switched on. Magnetic fields should be considered.

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).
• Removable inductors and ferrites that are consumables.

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

ELECTRICAL DIAGRAM

TECHNICAL TABLE

| 10R
---|---
Power| 1250 W
Operating voltage| 230 V +/- 15%
Power supply frequency| 50 Hz – 60 Hz
Heater Frequency| 45-100 kHz
microprocessor controlled
Number of conductors| 2 + Terre
Power supply cable length| 2 m
Inductor cable length| 1,5 m
IP Code| IP 21
Weight
generator + inductor| 4,8 kg
Weight
inductor only| 1,3 kg
Dimensions| 20,7 x 14,7 x 10 cm

SPARE PARTS

(UK : C51138)
3| ON-OFF switch| 52460
4| Fan| 51048
5| Bulkhead passage| 43120
6| cable inductor| 95095
7| Knurled nut| 56230
8| Collet chuck| 90898

includes all the grey part on the diagram

PICTOGRAMS

| User manual symbol
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| Warning Notice – Read the user manual
| To be used indoors – Must not be exposed to the rain.
| Explosion risks – explosive gases
| Danger, pressurised bottle
| Wear goggles
| Wear gloves.
| Wear protective clothing.
| Risk of flames
| Hot surface.
| Warning, electrical danger
| People wearing a pacemaker must not get any closer
| Magnetic fields emissions
| Electromagnetic field emissions
| No metal items or watches
| People wearing metal implants must not enter the area
| Earthing (for protection)
| Not intended to be used on a residential site where
the electric current is supplied by the public network, with a low voltage power supply (not class B).
| CE marking
| EAC marking
| Equipment in compliance with British requirements.
| Equipment in conformity with Moroccan standards.
| Do not dispose through regular domestic waste
| Temperature indication
| Triman
| Alternative current symbol

GYS SAS
1, rue de la Croix des Landes
CS 54159
53941 SAINT-BERTHEVIN Cedex
FRANCE

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