GYS POWERDUCTION 37LG Induction Heating System User Manual

GYS POWERDUCTION 37LG Induction Heating System User Manual

POWERDUCTION
37LG / 39LG / 50LG

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ASSEMBLY

50LG

39LG

37LG (si option chariot / if trolley option)

IMPOUNDMENT OF THE RESERVOIR

Reaction of the indicator lights

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 may only be used to heat ferrous materials within the limits indicated on the equipment and 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 charger if the mains cable or plug is damaged.
Do not cover the device.

• 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, potentially mortal for humans.
• If the ventilation is insufficent, use an approved respiratory unit.
• Read the safety data sheets (MSDS) and the manufacturer’s instructions for adhesvies, flux, metals, consumables, coatings, cleaning 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 approved repiratory/filtration unit. Make sure that a qualified person 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.

TRIMAN symbol
«This product should be recycled appropriately».

PRODUCT IDENTIFICATION

At the back of the product, there is an identification plate on which the CE marking is affixed:

• Name and address of the manufacturer
• Date of manufacture
• Model
• Product Type
• Operating Voltage

This data must be specified for each maintenance intervention, or if spare parts are requested.

PRODUCT SPECIFICATIONS

DESCRIPTION OF THE MACHINE (FIG I, II & III)

FIRST USE

The POWERDUCTION 50LG is supplied with an 8 m power cable fitted with a 5 poles 32 A 50Hz/60Hz plug. For optimal performance, the machine must be connected to a power supply network with a 32 A protection, and protected according to the applicable standards. The product is supplied with a 32A to 16A adapter. It allows the machine to operate on a 16 A plug with proper protection for short periods e.g. to remove seized bolts (see connection instructions).
The POWERDUCTION 37LG and 39LG are supplied with power cable (37LG : 2 m, 39LG : 4 m) fitted with a 2 poles + earth 16 A 50Hz/60Hz plug.

1. Once the product is assembled, place the lance on its support (50LG) or so that it points upwards (39 & 37LG).
   Remove the cap of the lance and the cap of the tank. Remove the torch cap and the tank cap.

2. Fill up the tank to the maximum using cooling liquid.

3. Place the torch above a bucket.

4. Connect the machine to the mains.
   Switch on the machine (1).

5. The machine starts and will systematically display Error 7.

6. Press the accessory change button (10) twice. The purge cycle takes 5 seconds (a loading icon should be displayed during it) and a double «beep» sound indicates completion.

7. As soon as the liquid is coming out of the torch, stop the torch by pressing the torch button, the accessory change button or the heat authorisation button. Or wait for «E-6» to be displayed.
   If Error 7 is displayed, start again from step 6 (five times max, see default E-7 explanation).

8. Screw the inductor on using a maximum coupling of 7Nm.

9. Press the accessory change button (10) twice. The purge cycle takes 5 seconds (a loading icon should be displayed during it) and a double «beep» sound indicates completion.

10. The temperature of the cooling liquid and the power instruction are displayed.

11. Top up the tank with cooling liquid if required.

12. Close the tank using the cap supplied with the accessories. The machine is now ready to be used.

Solving fault E-7
If the issue remains, check that the pump is working correctly or that the pipe is not blocked.
After five unsuccessful purge cycles, it is possible to:

• Stretch the torch above the machine to clear any pocket of water and for the pump to kick in.
• Put the machine at a 30° angle towards the torch.
• It is possible to blow the torch. Use an air blower and a cloth to keep it water proof and avoid projections.
• Re-attempt one or two cycles after each action.

If the issue remains, check that the pump is working correctly or that the pipe is not blocked.

INSTRUCTIONS

1. Set the main switch (1) to ON.
   The machine initialises in 2 seconds.

2. Press the heat authorisation button (2) as described on page 11. The indicator on button (2) and the lance support LED (12) both switch on, indicating that the machine is ready to operate.

3. Position the inductor (13) flat on the workpiece (place the open part of the ferrite towards the workpiece).

4. Press the button (11) on the lance to start the heating; if necessary move the inductor to heat a larger area. Two indicators indicate that the heating is active:
   – The brightness of the LED illuminating the inductor (12) decreases*.
   – The minimum power indicator light on the heating power indicator (3) flashes quickly (in HI mode both min & max lights flash).

It is possible to change the rated power during the heating.

  The heating set point can be set to Hi. The power is identical to the 100% mode but the Power duction behaves differently:

• At 100%: he wears the part red and maintains the right power for a few seconds before slowly reaching its maximum power.
• In Hi mode: it rises to its maximum power regardless of the condition of the room to be heated.

Remain very vigilant, the heating is strong and fast and may damage the part without a control of this mode.

The display provides a continuous update of the cooling liquid temperature (max 60°C/140°F).

• During the powering up phase, the pump and the cooling fan activate for a few seconds, to check that they are working properly.
• After the heating stops, let the cooling circuit operate to cool down the inductor, before switching off the machine.
• To modify the cooling liquid temperature unit, press and hold both settings buttons (4) until the desired unit is displayed (“ -F-” = Farenheit / “ -C- ” = Celsius). Release the buttons, the change is saved and in effect.

The machine has been designed to minimise the risks due to electromagnetic fields. Some residual risks persist and it is recommended to observe a security distance between the inductor and the operator’s head/torso.

Heat on standby
For security reasons, the product deactivates the heat authorisation after 5 minutes of inactivity. The heat authorisation button indicator and the lance support LED both switch off.
To reactivate the machine, press the heat authorisation button (2) or press and hold the lance button (11) for 1 second.
This feature is disabled after 20 minutes of inactivity.
It allows the user to stay in a working position without the need to reach for the machine.

INDUCTOR PRESERVATION

The heated metal radiates heat on to the inductor at the square of the temperature to which it is heated. The inductor is therefore highly exposed. When the metal is dark red, the temperature is below 850°C. If it turns bright red/ orange, the temperature exceeds 1000°C. If it turns white, the temperature exceeds 1200°C (the chart below is available in colour on the website manual).

NB : In the event of a warning alarm, the machine does not work.
The machine is fitted with several protection systems against electrical overcharge and cooling faults. The thermal protection of the inductor is mainly used when heating stainless steel, copper or aluminium parts. To reactivate the machine, simply wait for the cooling phase to end. For other protections, switch off the machine using the main switch and switch it back on.

For fault alarms E-6 and E-7, check that there is no leak or an obstructed/broken hose, that the pump is not blocked or deactivated and that there is enough cooling liquid in the tank.
If the problem appears to have been rectified, press the «inductor change» button twice (10) . The cooling circuit is performing a purge cycle. It is ready to operate.

**TIME DELAY MODE***

• Valid only for Powerduction versions of V4 program versions. Previous versions are not equipped with this function.
  The “Timing” function allows you to control the heating time of the Powerduction.
  The time is adjustable from 1 to 30 s.

To enter this mode:

1. Press the heating authorization button (2). Its indicator light comes on.
2. Then press both power adjustment buttons (4) simultaneously. The display shows “SEC” then “T 00” or “SEC” then “ON” if a time has already been set.
3. The power setting buttons (4) become time setting buttons. Change the setpoint from time to time as desired.

If the time value has not been changed beyond 3 seconds and still shows “T 00”, the Powerduction returns to normal mode.

Use in “Timer” mode:
Once the time setpoint has been selected, the product is ready for operation. The lighting LED (12) is lit.

1. Press the lance button (11). The intensity of the LED (12) decreases to indicate that the heating is active.
2. The heating stops at the end of the time limit. As long as the lance button (11) is pressed, the LED (12) and the heating enable button (2) flash to warn that the power is off. Adjust the time setpoint if necessary.
3. Press the lance button (11) for a new heating cycle.

Exit the “Timer” mode
The mode remains active at all times, even when the Powerduction is switched off and then on again.
1. To exit the mode, set the time setpoint on ∞ or press both power control buttons (4) simultaneously. The Powerduction returns to normal operating mode. The display shows “SEC” then “OFF”.

Special feature of the power setting in this mode
As explained, in normal use mode the setting buttons allow you to change the power while in this mode they change the time setpoint. To change the power without leaving the mode:
1. Press the heating authorization button (2). Its green light goes out.
2. The setting buttons (4) allow you to change the power. Adjust the power.
3. Press button (2) again. Its indicator light comes on again. The setting buttons (4) become the time setting again.

« ACCESSORY CHANGE » MODE

The pump activates. For 5 seconds, the LEDs display a wait pattern.
If the flow is correct, the machine emits a double «BEEP» and the product is ready to operate.
Otherwise a fault is displayed (refer to the fault code table).

Inductors and Adapters

« PURGE » MODE (39LG & 50LG)
This mode is only available if the heat is not activated (green switch is off).

1. Push the button (10), the pump stops and the LED (9) lights up.
2. Position the torch on its support and place the cable on the floor (to avoid liquid spillage).
3. Unscrew the accessory using key 27 (supplied with the machine).
4. Push and hold the heat authorisation button (2) for 3 seconds until it lights up.
5. Place the torch button above a bucket with a capacity of 10l minimum.
6. Push the torch button (11). The pump activates until the debit falls under 1l / minute or for 2 minutes. The machine displays the debit in decilitre per minute.
7. To interrupt the pump during the cycle, push any button.
8. To empty the cooling circuit, use a blower to blow air (30PSI) at the end of the torch until you can hear the air flowing or projections of liquid coming out of the tank.
9. To empty the tank, use a pump or push the machine forward in order to have it at an angle.

10. To top up the cooling liquid, refer to the installation instructions.

It is advisable to change the coolant every year if you are using it intensively, otherwise the Powerduction lance will deteriorate.
Prefer the use of the special welding coolant offered with Powerduction (see § Maintenance).

« PURGE » MODE (37LG)
This mode is only available if the heat is not activated (green switch is off).
1. Place the inductor, making sure it points upwards. Place the cable on the floor to avoid liquid spillage.
2. Unscrew the accessory manually.
3. Place the torch button above a bucket with a capacity of 10l minimum.
4. To empty the tank, place the product button above a bucket with a capacity of 10l minimum and lean the product on the back.

It is advisable to change the coolant every year if you are using it intensively, otherwise the Powerduction lance will deteriorate.
COOLING CIRCUIT AND «FORCED COOLING» MODE (39LG & 50LG)
To prevent the cooling liquid’s temperature from rising, the cooling fan starts, in any event, when the liquid’s temperature reaches 35°C (95°F). As soon as the temperature goes below that, the cooling fan switches off.

During long periods of use, the POWERDUCTION has a forced cooling mode. To activate it :

1. Set the main switch (1) to ON.
The machine initialises in 2 seconds.
2. Press the activation button (2) as described on page 5. The indicator on button (2) and the lance support LED (12) both
switch on, indicating that the machine is ready to operate.
3. Hold (>3 seconds) the button (10). The « Forced cooling» mode is activated.

The cooling fan then starts automatically. The cooling fan will be audible and the «Fan ON» message will appear on the display.
To stop the «Forced cooling», press the activation button to stop the heating or hold the button (10) again. The message «Fan OFF» is displayed.

MAINTENANCE

General recommendations
• It is advisable to change the coolant every 2 years at the latest, regardless of use, otherwise the POWERDUCTION lance may deteriorate.
• Prefer the use of the special welding coolant offered with Powerduction. Do not use automotive fluids, only coolants with low electrical conductivity.
• Prefer the use of the special welding coolant offered with Powerduction. Do not use automotive fluids, only coolants with low electrical conductivity.

• It is essential that the maintenance of the product is performed by qualified, authorised staff, that is fully aware of the recommendations outlined in this manual.
• Never clean, lubricate or perform maintenance on the product when it’s being used.
• Before any maintenance work, set the On / Off switch to « 0 » to switch off the machine, .then disconnect it it from the mains power supply to prevent any electrical shock or other risks resulting from improper handling.
• Do not wear rings, watches, jewellery, hanging clothes (e.g. ties), torn clothes, scarves, unbuttoned or unzipped jackets, or anyhting that could get caught during the operation of the machine
• Rather wear clothing specifically designed for the prevention of accidents, such as: non-slip shoes, anti-noise helmets, protective goggles, safety shoes, etc …
• Never use petrol or flammable solvents to clean the product. Prefer the use of water and, if necessary, non toxic commercial solvents.
• After maintenance, always put and secure the metal covers back on, before switching the machine on.
• The ferrite on inducer can be replaced if damaged.

To replace it, you must :
– Remove the protection,
– Remove the ferrite on copper with a heat gun to facilitate the removal of the resin,
– Clean copper,
– Glue the ferrite with the specific resin,
– Reposition the ferrite with its protection,
– Waiting for the complete setting of the adhesive before using the inductor.

Preventive maintenance
Meticulous inspections should be carried out at regular intervals to quickly detect and eliminate faults, so they will not cause damage to the device.

Prior to each use of the POWERDUCTION, check the unit’s security systems and any anomalies that may hinder the proper operation of the device. Perform daily checks to identify signs of wear.
The operational safety of the product can only be guaranteed if the repairs are carried out using original spare parts, and if the maintenance instructions are followed.

After each use and once the product is switched off, it should be cleaned immediately to remove any dust or dirt that may impair cooling efficiency, affect the proper functioning of the product and reduce its lifespan.
Before each use, check the good operation of the main systems, security systems, and all the electrical cables connection.

Perform periodic visual inspections to verify that there are no cooling liquid leaks, and check that the vents are not obstructed.

ELECTRICAL CONNECTIONS

The product is designed to operate on a single phase power supply from 165 V to 265 V,

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).
• Inductors and removable ferrites that are consumables.
• Use of unspecified coolant.

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

COOLING CIRCUIT DIAGRAM

DISTANCES EMS

POWERDUCTION 39 LG

POWERDUCTION 37 LG

SPARE PARTS

POWERDUCTION 50LG

POWERDUCTION 39LG

POWERDUCTION 37LG

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