GYS Powerduction 160L Bedienungsanleitung

Warranty ...................................................................................................2

Identification of the machine ......................................................................2

Product specifications.................................................................................2

Dimensions and weight...............................................................................2

Normative references .................................................................................2

Using this manual.......................................................................................3

General notes on safety..............................................................................3

Recommendations of use............................................................................3

Constructions features................................................................................4

Signs and warning signs .............................................................................4

List of protections.......................................................................................4

Control panel description............................................................................5

Instructions of use .....................................................................................6

Residual risks.............................................................................................6

Noise and vibrations...................................................................................6

Demolition and disposal..............................................................................6

Unpacking and installation..........................................................................6

Electrical connection...................................................................................6

Using the machine......................................................................................6

Replacing the inductor................................................................................6

Maintenance ..............................................................................................7

Electrical connections .................................................................................8

Electrical diagrams .....................................................................................9

Cooling liquid circuit diagrams.....................................................................10

RoHS declaration of compliance..................................................................11

CE declaration of conformity.......................................................................11

User manual

053472_01 01 2015_V1 - 1 -

WARRANTY

Upon delivery, the buyer will have to make sure that the machine is complete. Deficiencies and anomalies must

be reported. Any attempt to change any part of the machine, CE marking, the declaration of conformity and / or

the manufacturer's declaration will invalidate the warranty.

The manufacturer is also considered exempt from liability arising from the following cases:

- Incorrect installation;

- Improper use of the machine by personnel not adequately trained;

- Safety regulations not respected;

- Lack of maintenance;

- Modification of the machine or use of non-original parts for repair.

IDENTIFICATION OF THE MACHINE

An identification plate can be find at the back of the machine on which in addition to CE marking is reported :

•Name and address of the manufacturer

•Date of manufacture

•Model

•Type of machine

•Weight

•Voltage

These data must be mentioned whenever it requires technician’s intervention or spare parts request.

PRODUCT SPECIFICATIONS

Induction heater.

Power: 16.0 kW

Voltage: 400 V

Mains frequency : 50 Hz

Heater frequency : 15 kHz.

Insulation Class II, No. of poles: 3.

Cooling liquid : provided. Standard automotive cooling liquid (water + 30% max. glycol).

Power lead : 10 m.

Inductor cable : 4 m.

DIMENSIONS AND WEIGHT

Weight 190 kg, height 1100 mm + 96 mm wheels

Width 500 mm

Depth 600 mm

NORMATIVE REFERENCES

Directive CE2004/40 / Exposure to electromagnetic fields

Low Voltage Directive CE 2006/95

Machinery Directive 2006/42/EC

EMC Directive 2004/108/EC

Directive 2002/95/EC

EC Directive 2002/96

053472_01 01 2015_V1 - 2 -

USING THIS USER MANUAL

It is very important that this user manual, designed to provide user with general knowledge of the machine, as

well as instructions for use and maintenance necessary for operating, is kept with the machine or in a safe place

for future reference.

The user manual, as mentioned by the law, is an integral part of the machine and must be with it until its

destruction.

The warnings given must be read carefully, for safety reasons, before installation and use. It is prohibited for

any reason to modify this manual without the written permission of the manufacturer.

GENERAL SAFETY NOTES

The machine is designed for a professional use. Its durability and reliability will be more effective if it is correctly

used and regular maintenance is done.

Always read the instructions contained in this manual, they provide important safety information.

RECOMMENDATIONS OF USE

This machine should be used only for the purpose for which it has been designed: heating metals. Any other use

not expressly mentioned in this manual is strictly forbidden and dangerous. The machine is semi-automatic and

requires the presence of the operator.

WARNINGS :

The operator has the responsibility to respect, not only for him, but also those who may be exposed to the risks

of the machine, all the rules that relate to safety. Before performing any operation with the machine, carefully

read this manual, as it gives guidelines and procedures to operate the product correctly and safety.

•The machine must be only used by trained operators and in full compliance with local regulations and

instructions contained in the manual.

•Strictly follow the signs and mandatory warnings on the machine.

•Before any maintenance electrically isolate the machine to prevent accidental.

•In case of damaged or broke of cooling hoses or electrical cables, act promptly to replace them.

•In case of cooling liquid leaking, the floor must be cleaned to avoid risks of people falling.

•Do not leave the equipment exposed to bad weather (rain, wind, etc…).

•Do not leave the equipment unattended with children around.

•If you decide not to use the equipment, make it inoperative and respect practice related to disposal in

accordance with law.

The following recommendations should be strictly followed by users, in order to

prevent risks of material damage, or people injuries.

053472_01 01 2015_V1 - 3 -

MANUFACTURING FEATURES

The machine is designed and built in compliance with the essential health and safety requirements laid down by

the Machinery Directive 89/392 EEC and subsequent amendments.

In particular, given that the operator is in direct contact with the machine :

•Remove sharp edges and sharp angles;

•Place the machine in a stable position;

•Ensure that the operator cannot come into direct contact with live parts which may cause electrical shock or

injury.

And everything else needed to secure its use.

The main parts of the POWERDUCTION can be summarized as below:

1) ON/FF switch

2) Control panel

3) Inductor

4) PCB

5) Fan

6) Cooling unit

Signs and warning signs

On the machine are placed signal warnings and mandatory warnings that the operator must follow for his

personal safety and security.

Protections

The machine is safe to use, however it is recommended to be careful during

operation as heated materials can burn on contact for a long time after the

passing the inductor. The inductor itself, even if continuously cooled, may

become warm on red heated parts and therefore there is a risk of burns.

The machine is equipped with several electronic protection systems against

electrical surges and overheating. The thermal protection of the inductor

mainly occurs when heating parts in metallic alloys. To restart the machine,

release and press again the button. For all the other protections, switch off

the product using the ON/OFF switch.

Finally there are 2x 32 A fuses on the heating circuitry (fuse holder under the

metallic cover of the product).

The fuses should only be replaced after the default has been repaired.

053472_01 01 2015_V1 - 4 -

CONTROL PANEL DESCRIPTION

1 General ON/OFF switch

2 Power setting buttons

3 Power indicator (1kW – 16 kW).

4 Induction heating activation

5 Alarm indicator – Cooling circuit

6 Heating indicator (ON=heating; blinking = stand-by).

7 Inductor switch

8 Inductor (ferrite)

9 Cooling liquid temperature alarm (machine stopped)

10 Inductor alarm (wrong inductor or short-circuit)

11 Cooling liquid temperature

« Alarm » indicators :

The alarm indicators above mean, from left to right :

1. A cooling liquid temperature which is too high. Leave the product ON without using the inductor, in order for

the cooling liquid temperature to decrease.

2. An issue with the flow of cooling liquid (pump issue, blocked pipe).

3. A defective inductor; contact JBDC after sales or your local distributor.

Note : in case of alarm, the product does not heat up.

053472_01 01 2015_V1 - 5 -

INSTRUCTIONS OF USE

The product is delivered with a three-phase 400V / 50 Hz plug. In order to ensure an optimum use, the product

should be connected to an electrical installation with minimum 25A protection, and protected according to

applicable standards. See the instructions for electrical connections on page 8.

Turn the ON/OFF switch to the ON position. Press the induction heating activation button (4) described on page

5. The light on button 6 blinks indicating that the product is ready to heat. Position the inductor (8) flat on the

part or the area to heat up, placing the open part of the ferrite against the part. Press the trigger (7) on the

handle of the inductor to start heating; if necessary move the inductor in order to heat up a larger surface on

the part. After stopping the heating, decrease the heating power level on the control panel, and secondly only

switch off the product; this way the cooling circuit will reduce the temperature of the inductor before switching

off completely the product.

RESIDUAL RISKS

WARNING!

The machine has been designed to ensure maximum safety. It’s still possible that the operator may get burnt by

touching hot parts.

WARNING!

The machine must not be used near sensitive materials or dangerous explosives, compressed gases, flammable

liquids, electrical equipment.

Metal objects may not be worn close to the inductor, as they will become hot (rings for example).

It is forbidden for people wearing pace-makers or any other biomedical equipment to use this product.

Noise and vibrations

The machine produces a continuous sound level of less than 60dB (A).

The machine does not generate significant vibrations that may cause danger.

Destruction and disposal

Some materials, with which the machine is built, can be recycled; therefore recycling the product should be

performed in accordance with relevant local regulations.

Unpacking and installation

The machine is supplied ready to use. Before operating, you must remove all packaging and place the product in

a suitable place (flat ground, dry and ventilated place).

WARNING!

The installation must enable easy access to all of the machine’s parts. A minimum space around the product

must be respected for good operation and maintenance, without problems and risks for the operator.

Replacing the inductor

WARNING!

The replacement of the inductor should be performed only by authorized staff and only after switching off the

machine.

WARNING!

During maintenance and / or repair, wear protective gloves. Electrically isolate the machine by disconnecting it

from the mains.

WARNING!

It is forbidden to start using the machine if all the metallic side panel have not been screwed back on the

product and if all the safety features are not operational.

053472_01 01 2015_V1 - 6 -

WARNING!

This machine has been designed to reduce at the maximum the risks relative to exposure to electromagnetic

fields. However, residual risks may remain, and therefore it is recommended to respect a minimum safety

distance of 30cm between the inductor and the head or the chest of the operator.

MAINTENANCE

General recommendations

•It is essential that the maintenance of the machine is carried out by qualified and authorized personnel,

which is aware of the recommendations described in this user manual.

•Never perform any cleaning, lubrication or maintenance with the machine running.

•Before any maintenance work, turn the ON/OFF switch on "0" to turn the machine off, unplug it from the

mains to avoid electrical shock or other hazards resulting from mishandling.

•Do not wear rings, watches, jewellery, dangling clothing, such as ties, torn garments, scarves, unbuttoned

jackets or zip open that can be caught during operation.

•Instead, wear suitable clothes for accident prevention, for example: non-slip shoes, anti-noise headphones,

goggles, appropriate gloves, etc. ...

•Never use petrol or flammable solvents to clean the machine. Use water and, if needed, commercial non-toxic

solvents.

•After maintenance, always put back the metallic side panels of the machine before turn it on.

Preventive Maintenance

Meticulous inspections carried out at regular intervals of time are necessary in order to detect and solve faults

quickly before they can cause damage.

WARNING !

Every time using the IMS POWERDUCTION 160L,check first the safety features of the product, and

any anomaly which could lead to bad operation. Check daily wear of the machine.

WARNING !

The operational safety of the machine can only be guaranteed if repairs are carried out using only the original

spare parts and if approved maintenance instructions are carried out correctly.

After each use, with the machine turned off, the machine should be cleaned promptly, to remove dust or dirt in

general, because they may decrease ventilation and alter the proper functioning of the product and its

durability.

Before each use, check every control of the machine work, safety devices and the electrical connection cables.

WARNING !

Make periodic visual checks to verify that there are no leak and the vents are clear.

053472_01 01 2015_V1 - 7 -

ELECTRICAL CONNECTIONS

The product has been designed for 400V / 50 Hz three-phase electrical supply.

WARNING : do not use on a 60Hz electrical supply.

On a three-phase 400V electrical supply, connect the pins as shown below :

A specific order has to be respected when connecting the 3 phases. If this order is not respected, the

PHASE / ALARM LED will switch ON. Modify the order of the phases until the PHASE / OK - LED

switches ON.

053472_01 01 2015_V1 - 8 -

ELECTRICAL DIAGRAMS

053472_01 01 2015_V1 - 9 -

COOLING LIQUID CIRCUIT DIAGRAMS

1) Fan 1309000304

2) Radiator 1309000301

3) Thermostat 1309000406

4) Inductor junction box 1109000218

5) Flow detector 1109000413

6) Pump 1109000303

7) Tank 1309000302

8) Inductor 1109000218

Components and parts

This section contains a list of the components of this machine. Its contents may be used for identification of

spare parts. For rapid delivery of spare parts, please quote the following order:

1) Number in the list

2) Part number (design or commercial)

3) Name of part

4) Quantity

5) Serial number of the machine

6) Date of manufacture

053472_01 01 2015_V1 - 10 -

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