Indy User`s Manual
Contents
1. UD 9 9 H 9 Power 10 Time ee 10 Temperature ModE 11 ANAO MOC uestrum rete 11 EXTERNAL COMMUNICA TION 2 12 Input Output 1 0 12 13 MAINTENAN 14 14 14 TROUBLESHOOTING 509 15 INCEUDED IN SHIPMENJT 16 APPENDIX A SERIAL PORT COMMAND LIST sesenta nnne tnter tn nnns 17 APPENDIX B DECLARATION OF CE tn nnne 31 02012 High Frequency Power LLC dba iTherm Technologies Page 2 of 31 WARNING SAFE OPERATIONAL PROCEEDURES AND PROPER USE OF THE EQUIPMENT ARE THE RESPONSIBILITY OF THE USER OF THIS SYSTEM This equipment produces potentially lethal high voltage high current and high frequency HF power You should read this entire manual and understand its content before you attempt to power or operate the equipment it describes to avoid personal injury or death Follow all safety precautions Never defeat safety in2. Wi THERM For 24 Hour Technical Support Call 1 800 332 1111 Set A 3523 F391kHz HIG 1 4 CE Power Supply User s Manual P N HFP 7 P0101A103 January 2014 02012 High Frequency Power LLC dba iTherm Technologies All rights reserved Printed in the United States of America This manual is supplied to enable the reader to safely install and operate the equipment described herein Please read entire manual carefully prior to using your power supply In the interest of providing continually improved equipment to our customers iTherm Technologies reserves the right to make product changes without notification or obligation 2012 High Frequency Power LLC dba iTherm Technologies Page 1 of 31 CONTENTS WARNING iced ied aiii eum alius ot 3 Symbols Used In This Manual oie iden eee bro ridet a cea ae ce ie devia e de 3 RETURNING UNITS FOR REPAIR nuin redd rr Eros nii Pec le 4 Contact Informatio cocer tor tei asa Unis eric dud 4 POWER SUPPLY PARAMETERS ern pne pcm P ea hepatis c nc 5 COIEPARAMETERS eh usn 6 A BRIEF OVERVIEW OF 7 Important Application Considerations sees te tenen nins 7 INTERFACE onec usu M IEEE 8 POWER SUPPLY 9
3. Get Output Frequency Modulation Set Output Frequency Modulation Get Viper 1 Viper 2 mode Set Viper 1 Viper 2 mode Get Line Voltage Scaling Factor Set Line Voltage Scaling Factor Get Power Factor Set Power Factor Get Line Voltage Get analog input Gain and Offset Set analog input Gain and Offset COMMAND CHARACTER W COMMAND DATA BYTES NOT COUNTING COMMAND CHARACTER amp CHECKSUM 3 floats 212 bytes 0 Unsigned char 1 byte 0 Unsigned char Viper1 or Viper 2 mode Unsigned short 2 bytes Pulse in uSec Total of 3 bytes 0 Float 4 bytes 0 Float 4 bytes 0 Gain float Offset float 8 bytes 02012 High Frequency Power LLC dba iTherm Technologies RESPONSE Echo Unsigned char 1 byte Echo Unsigned char Viper1 or Viper 2 mode Unsigned short 2 bytes Pulse in uSec Total of 3 bytes Echo Float 4 bytes Echo Float 4 bytes Echo Short int 2 bytes Gain float Gain and Offset float 8 bytes Echo ECHO Yes No Yes No Yes No Yes No Yes No No Yes Page 20 of 31 COMMAND DESCRIPTIONS Command Character Description Valid Range Construction Reply Example Command Character Description Construction Reply Example Command Character Description Construction Reply 02012 High Frequency Power LLC dba iTherm Technologies Set
4. 2 FIGURE 1 Front panel Model HIG 1 4 CE Serial Number 09120xx ri RS 232 _ n J 5678 Input Output Voltage 110 250 Vac 0 900 V Current 10 A 0 80 A Frequency 50 60 Hz 0 750 kHz QACE ipn A Z iTherm Technologies US and foreign patents 85 Meadowland Dr US 7 034 264 S Burlington VT 05403 us 7 279 665 Ph 1 802 862 9976 PCTWO 2005 0005540 A www iTherm com Other patents pending FIGURE 2 Rear panel Front LCD Display I O Communication Ports HF Coil Connection Serial Communication Port Indicator Lights Green Running Cooling Fan Exhaust Yellow lt Standby Red Error E Mode Button Index Up D Button Run Trigger K Power Entry Module Fused 02012 High Frequency Power LLC dba iTherm Technologies Page 8 of 31 POWER SUPPLY OPERATION POWERING UP Powering up the HIG 1 4 is easy First ensure that the IEC320 C13 style power cord supplied is plugged firmly into the rear panel of the power supply and that the mains voltage supplied is within the limits specified in the POWER SUPPLY PARAMETERS section on page 5 The unit is then powered on by flipping the rear rocker panel switch upwards into the I position NoTE Information on the procedure for replacing the mains input fuse can be found in the MAINTENANCE section on page 14 CONNECTING A COIL To connect a HIG 1 4 compatible coil to the pow
5. If the parameter is set between 300 and 32767 then the power setting is maxed at 300 If the parameter is set between 32767 to 65535 then the power setting is wraparound to 0 The host will send a 4 byte message The first byte will be the A character the second and third bytes contain the power set point with the LSB in byte 2 and the MSB in byte 3 the fourth byte is the checksum The power supply will echo back the command If an invalid set point is transmitted the power supply will reply with the set point itis going to use The reply construction is identical to the command instruction To configure a set point of 150 Watts the host will send 0x41 0x96 0x00 OxD7 The power supply will reply with 0x41 0x96 0x00 OxD7 Get Power Set Point B Returns the current power set point The host will send a 2 byte message The first byte will be the B character and the second byte will be the checksum The power supply will reply with a 5 byte message The first byte is an echo of the B character the second byte is the number bytes remaining in the message 0x03 bytes 3 and 4 contain the power set point with the LSB in byte 3 and MSB in byte 4 the last byte is the checksum To retrieve the current power set point the host will send 0x42 0x42 The power supply will reply with 0x42 0x03 0x96 0x00 OxDB This shows the current power set point is 150 W Change to power mode D When issued before Run command this command swit
6. Should iTherm determine that your power supply requires service an RMA number must be obtained prior to returning your unit to iTherm Technologies An RMA can be easily obtained by contacting iTherm Following our RMA process enables appropriate follow up and rapid resolution for your repair CONTACT INFORMATION 24 Hour Technical Support 1 800 332 1111 www iTherm com contact Customer Service Toll free USA 1 802 862 9976 Int l 1 802 862 9976 Fax 1 802 864 3782 Shipping iTherm Technologies 85 Meadowland Drive South Burlington VT 05403 U S A 2012 High Frequency Power LLC dba iTherm Technologies Page 4 of 31 POWER SUPPLY PARAMETERS INPUT VOLTAGE INPUT CURRENT INPUT PROTECTION OUTPUT POWER OUTPUT FREQUENCY COOLING ENVIRONMENTAL RATING 110 240 VAC 10 50 60 Hz Single Phase NOTE for maximum power output operate at 240 VAC 6 A Max 6 3 A Slow Blow Fuse 240 VAC MOV 1000W maximum at 900V peak NorE Maximum available power depends upon coil parameters and load characteristics see page 7 for more details 36 500kHz NOTE Alternative coil configurations can be used to achieve target frequency Contact iTherm for custom coil options Air cooled via 3 high CFM auto engaging fans Air intake is on the bottom of the power supply exhaust is at the rear panel NOTE Sufficient clearance for the air intake is achieved with the unit s feet Do remove the feet
7. Temperature In Celsius a Configures the temperature set point in degrees Celsius with a resolution of 0 25 C 10 500 If the parameter is set to less than 10 C then the temp setting is set to 10 C If the parameter is set to more than 500 C the temp setting is wrapped around to 10 C The host will send a 4 byte message The first byte is the character a the second byte is the LSB of the temperature set point the third bytes is the MSB of the temperature set point The fourth byte is the checksum The desired value must be multiplied by 4 prior to sending see the example below The power supply will echo back the command If an invalid set point is transmitted the power supply will reply with the set point it is going to use The reply construction is identical to the command instruction To enter a set point of 200 0 the host will send 0x61 0x20 0x03 0x84 The power supply will reply with 0x61 0x20 0x03 0x84 Request Temperature Set Point in Celsius b Returns the current temperature set point in Celsius The host will send a 2 byte message The first byte is the character b and the second byte is the checksum The power supply will reply with a 5 byte message The first byte is an echo of the b the second byte is the number of bytes remaining 0x03 in the message including the checksum the third byte is the LSB of the temperature set point the fourth byte is the MSB of the temperature set point and the
8. and do not restrict the airflow into or out of the power supply Provide 2 3 clearance at the rear of the power supply to allow air to exit from the unit Periodic cleaning of the air filters is required for efficient cooling and safe operation IP 32 THIS EQUIPMENT REQUIRES A CONNECTION TO EARTH GROUND FAILURE TO CONNECT EARTH GROUND WILL RESULT IN A POTENTIALLY HAZARDOUS CONDITION 02012 High Frequency Power LLC dba iTherm Technologies Page 5 of 31 COIL PARAMETERS COIL INDUCTANCE 0 6 H 340 COIL RESISTANCE 5 300 ELECTRICAL ISOLATION Rated to 2kV ENVIRONMENTAL RATING IP 30 THE COIL CARRIES HIGH FREQUENCY HIGH VOLTAGE AND HIGH CURRENT ELECTRICAL SIGNALS AND MAY PRESENT A SHOCK HAZARD ALTHOUGH THE COIL IS ELECTRICALLY ISOLATED PHYSICAL CONTACT WITH THE COIL IS NOT PERMISSIBLE ANY CONDUCTIVE OBJECTS CONTACTING THE COIL AND OR COIL HOUSING SHOULD BE PROPERLY CONNECTED TO AN EARTH SAFETY GROUND USE ONLY HF COILS AND CONNECTORS SUPPLIED BY ITHERM TECHNOLOGIES IN ORDER TO ASSURE PROPER SAFETY RATING AND OPERATOR SAFETY ALL CUSTOM COILS MUST BE APPROPRIATELY ELECTRICALLY INSULATED FROM CONTACT ITHERM ASSUMES NO RESPONSIBILITY FOR UNIT FAILURE OR INJURIES DEATH RESULTING FROM THE USE OF COILS NOT SUPPLIED BY ITHERM DO NOT ALLOW COIL LEADS TO BECOME EXCESSIVELY HOT EXCESSIVE STIFFNESS IN THE COIL LEADS CAN BE A SIGN OF IMPENDING COIL FAULURE AND MAY AFFECT YOUR POWER SUPPLY PROLONGED THERMAL
9. that the mains plug is disconnected prior to replacing the fuse EXERCISE CARE WHEN REMOVING THE BLOWN FUSE AS THE GLASS CASING CAN OFTEN BE CRACKED OR SHATTERED IF THE REPLACEMENT FUSE BLOWS IMMEDIATELY WHEN THE POWER SUPPLY IS TURNED BACK ON OR POWER IS CYCLED TO THE COIL CONTACT ITHERM AS YOUR POWER SUPPLY MAY REQUIRE REPAIR FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH A 20MM X 5MM SLOW BLOW 6 3A 250 VAC RATED FUSE FOR EXAMPLE LITTLE FUSE INC PART NUMBER 021806 3HXP 02012 High Frequency Power LLC dba iTherm Technologies Page 14 of 31 TROUBLESHOOTING In the event of an error the front LCD will display information regarding the nature of the error The following table describes possible errors the power supply may encounter during operation and the corrective action required Emo Description of Cause Corrective Action LCD displays ERROR CONNECT COIL LCD displays ERROR INVALID LOAD LCD displays ERROR INTERNAL OVERHEAT Indicator lights and front display not on Blank screen and LED light s illuminated Blank screen and LED light s illuminated A coil has not been connected to the power supply or the coil has suffered an open circuit failure A coil with an inductance outside the acceptable range is connected to the power supply This error can also occur if the connected coil has become damaged The temperature of the power supply s internal components
10. the desired power set point is achieved press the mode button once to cycle into time mode 3 Usethe T and lt arrows to specify a desired run time Press the I O button to deliver power to the coil The time setting will automatically count down and stop the flow of power to the coil once the timer reaches zero Note that while the machine is running the operator is free to use the T and arrows to deliver more or less power in real time to the coil 5 If the flow of power to the coil needs to be stopped prematurely press the I O button once to promptly do so The timer will automatically reset and ready itself NOTE If more power is requested of the power supply than the power supply is able to deliver into that part for reasons specified in the IMPORTANT APPLICATION CONSIDERATIONS on page 7 the power supply will automatically calibrate itself and run at the maximum allowable power once the I O button is pressed In this scenario the power supply operator will not be able to increase the output power setting 02012 High Frequency Power LLC dba iTherm Technologies Page 10 of 31 TEMPERATURE MODE The top line of the LCD will display Set Temp to indicate when the unit is in temperature mode Temperature mode operates in closed loop control such that the power supply will self modulate its output power to achieve and maintain a user specified temperature set point This requires an external feedback system The standard exter
11. the power supply will reply with Ox4E 0x02 0x10 0x60 Decomposing the message we get output modulation frequency of 10Hz Set output modulation frequency O capital letter 0 Sets the output modulation frequency N A The host will send 3 bytes The first byte is the character O the 2 9 byte is the output modulation frequency in Hz the 3rd byte is the checksum Page 27 of 31 Reply Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range 02012 High Frequency Power LLC dba iTherm Technologies The power supply will echo back the command The reply construction is identical to the command construction To set the output modulation frequency to 16 Hz the host will send Ox4F 0x10 Ox5F The power supply will reply with Ox4F 0x10 Ox5F Get Viper1 Viper 2 mode P capital letter P Returns Viper 1 vs Viper 2 mode and the pulse length when running in Viper1 mode N A The host will send a 2 byte message The first byte is the character P and the second byte is the checksum P The power supply will send a 6 byte message The 15 byte is an echo of the P the 21 byte is the number of bytes remaining in the message 0x04 including the checksum the 3 byte 0x01 for Viper 1 mode or 0x02 for Viper2 m
12. CONTACT WITH THE FLUX CONCENTRATOR WHERE APPLICABLE CAN ALSO LEAD TO COIL FAILURE OR CHIPPING OF THE FERRITE 2012 High Frequency Power LLC dba iTherm Technologies Page 6 of 31 A BRIEF OVERVIEW OF INDUCTION iTherm s induction heating power supplies work by generating a strong rapidly oscillating magnetic field that is produced from the passage of high voltage current through the coil The shape and direction of this magnetic field is skillfully chosen and manipulated purposefully into the work piece through the use of our customized flux concentrators and unique coil designs When the magnetic field lines encounter an electrically conductive material the work piece its energy is transferred into the work piece by the creation of eddy currents that flow in opposition to the magnetic field The internal resistance to the flow of these eddy currents within the work piece material is the mechanism that produces heat IMPORTANT APPLICATION CONSIDERATIONS Inductive heating is only effective with materials that are electrically conductive Inductive performance is crucially related to material selection of the work piece and can vary greatly due to O PERMEABILITY The ability for a material conduct hence support dense magnetic flux lines This can vary from as low as gt 1 copper silver lead to just greater than 1 aluminum magnesium or be as high as 250 5000 cobalt nickel iron RESISTIVITY The interna
13. ECKSUM ALGORITHM The protocol used in this application utilizes a single byte binary checksum The checksum is calculated as the remainder from the division of the sum of all preceding characters in the message by 256 i e n CS gt Messagedi mod256 i Equation 1 Checksum equation In practice the checksum is calculated by summing the values of all the message string bytes into a variable which is one byte wide ignoring any overflow that may occur INVALID CHECKSUM ACTION If an invalid checksum is received with any of the commands that require echoing back the power supply will ignore the command and echo the received byte sequence to the host If an invalid checksum is received with any other command not requiring echo the checksum will be ignored INVALID PARAMETER RECEIVED If the power supply receives a command with an invalid parameter for example set maximum temperature allowable maximum temperature or mode being changed while the power supply is running the power supply will ignore the invalid parameter and echo with the value to be used the most recent accepted valid value 02012 High Frequency Power LLC dba iTherm Technologies Page 17 of 31 TEMPERATURE COMMUNICATION Temperature communication supports both and for SetTemp and GetTemp however only reports temp in as part of the CurrentStatusStruct defined below ECHO The following commands will be echoed Set Temperature Set Pow
14. LARATION OF CE CONFORMITY Declaration of Conformity In accordance with ISO IEC 17050 DoC 090601 iTherm Technologies 166 W Lakeshore Drive Colchester VT 05446 USA Induction Heating Equipment Model HIG 1 4 CE is complaint with the CE directives and standards listed below Directives Electromagnetic Compatibility 2004 108 EC Low Voltage 2006 95 EC Standards EMC EN 61326 1 2006 Industrial Safety EN61010 1 2001 EN 60204 2006 This product was tested by an ISO 17025 accredited facility This manufacturer employs an internal pr duction control system which assures compliance between the manufactured products and the technical documentation BY UAn Date DUWE 0 2004 Stefan Von Buren Director of Operations iTherm Technologies L P 02012 High Frequency Power LLC dba iTherm Technologies Page 31 of 31
15. N TRIGGERED BY THE SAME METHOD TRIGGERING EXTERNALLY DEACTIVATES THE BUTTONS ON THE FRONT PANEL TO USE THE FRONT PANEL AGAIN YOU MUST FIRST DEACTIVITE THE TRIGGERED EVENT WITH THE EXTERNAL TRIGGER 02012 High Frequency Power LLC dba iTherm Technologies Page 12 of 31 SERIAL PORT If additional control over the power supply is required beyond that of the I O pins functionality the serial port is provided to allow the operator to full control of the power supply using a computer Communication with this port requires a straight thru not a null modem DB9 RS 232 cable and a corresponding RS 232 port or USB adapter on the host computer For a complete list of serial port commands please refer to APPENDIX A SERIAL PORT COMMAND LIST on page 17 In addition to offering full control of the power supply externally the serial port can also be used to remotely reprogram the power supply This is useful when a custom firmware installation is required or a firmware update is available as it negates the need to return the power supply to iTherm for service In the event of a mandatory reprogramming of your power supply iTherm will provide you with 3 files necessary to complete the firmware change boot bat 16 Bit Flash Programmer exe and s3 hex The following steps will need to be followed to successfully reprogram your power supply 1 Download and store all the aforementioned files into the same location on your hard drive boot bat points t
16. Voltage N A The host will send a 2 byte message The first byte is the character V and the second byte is the checksum V The power supply will send 5 byte message The 15t byte is an echo of the the 218 byte is the number of bytes remaining in the message 0x03 including the checksum the 314 4th bytes are a 16 bit integer representing the line voltage in Volts and 5 byte is the checksum To request the line voltage mode the host will send 0x56 0x56 If the line voltage is equal to 240 V the power supply will reply with 0x56 0x03 OxFO 0x00 0x49 Get analog input gain and offset Returns the analog input gain and offset in mV N A The host will send a 2 byte message The first byte is the character W and the second byte is the checksum W The power supply will send an 11 byte message The first byte is an echo of the W the second byte is the number of bytes remaining in the message 0x09 including the checksum the next four bytes are a float representing the gain LSByte first the next four bytes are a float representing the offset LSByte first And the 11 byte is the checksum To request the analog input gain and offset the host will send 0x57 0x57 If gain 1 0 and offset 1mV then the power supply will reply with 0x57 0x00 0x00 0x80 0x3F 0x00 0x00 0x80 Ox3F OxEO Decomposing the message we get the gain 1 0 and offset 1 0mV Page 30 of 31 APPENDIX B DEC
17. are a float representing the gain LSByte first the 7 and 8 bytes are a short representing the thermocouple offset LSByte first And the 9 byte is the checksum NOTE The offset value is in quarters of deg C see the example below To request the TC gain and offset the host will send 4 4 If gain 1 0 and offset 1C then the power supply will reply with 4 0x07 0x00 0x00 0x80 Ox3F 0x04 0x00 0x14 Decomposing the message we get the gain 1 0 and offset 1 C Set Thermocouple gain and offset K Sets the thermocouple gain and offset in Celsius with a resolution of 0 25 C N A The host will send an 8 byte message The first byte is the character K the next four bytes are a float representing the gain LSByte first the 6th and 7 bytes are a short representing the thermocouple offset LSByte first And 8 byte is the checksum The power supply will echo back the command The reply construction is identical to the command construction If the checksum failed then the power supply will echo the message with the failed checksum and will not update the internally used parameters If the power supply failed to store the new values in EEPROM then the power supply will change the internally used parameters to defaults gain 1 and offset 0 and send them to the host Contact iTherm in this case To set the TC gain lt 1 0 and offset 1C the host will send Ox4B 0x00 0x00 0x80 Ox3F 0x04 0x00 OxOE T
18. ches the power supply to power mode The command has no effect if issued while the power supply is running the power supply would echo back the current mode The host will send a 2 byte message The first byte is the character D and the second byte is the checksum The power supply will echo back the current mode with checksum To change to power mode the host will send 0x44 0x44 The power supply will reply with 0x44 0x44 Get current status p Returns the current status of the power supply The host will send a two byte message the first byte will be the command p and the second byte will be the checksum Page 24 of 31 Reply The power supply will reply with a 15 byte message The first byte is an echo of the command p Bytes 3 and 4 contain the thermocouple value with the LSB in byte two Bytes 5 and 6 contain the current power output from the generator in watts with the LSB in byte four Bytes 7 to 10 contain the time set point in milliseconds Bytes 11 and 12 contain the status bits Bytes 13 and 14 contain the error bits and byte 15 is the checksum Example request the current status host will send 0x70 0x70 The power supply will reply with 0x70 0 0 0x78 0x00 0x00 0x00 OxFF OxFF 0x00 0x00 0xA6 0x00 0x00 0x04 0 9 Decomposing this example we see TC1 Value 0x0078 120 4 30 Power Output 0x0000 OW Timer 0x0000FFFF 65535ms Current Status 0x006A 0b10100110 0 Running 0
19. em that automatically measures the coil and load characteristics every time power is cycled to the coil Each time this occurs the power supply will adjust the modulation of the output pulse accordingly to deliver the correct amount of power requested by the current setting This system negates the need for any scheduled calibration as calibration is automatically built into the machine s functionality CLEANING AIR FILTERS Periodic cleaning of the air filters on the bottom of the power supply is required for efficient cooling and safe operation The air filters on the bottom of the power supply should be vacuumed at least once a month or more depending upon the conditions of your production environment Always ensure that the unit is off and that power is disconnected when vacuuming the air filters ADEQUATE AIRFLOW INTO AND OUT OF THE POWER SUPPLY IS ESSENTIAL FOR SAFE AND RELIABLE OPERATION OF THE UNIT ALWAYS PROVIDE AT LEAST 2 3 OF CLEARANCE AT THE REAR EXHAUST TO ALLOW AIR TO EXIT NEVER REMOVE THE FEET ON THE BOTTOM OF THE POWER SUPPLY ELSE THE AIR INTAKE WILL BE RESTRICTED REPLACING FUSE Each power supply is equipped with an input protection fuse Should the input protection fuse need to be replaced it can be located in the slide out compartment between the rear power switch and the AC mains input plug in the power entry module The slide out compartment is also equipped with a spare fuse Always ensure that the power supply is off and
20. er Set Time Set PID Parameters Set Output Frequency Modulation Set TC Gain and Offset Mode Power Mode Time Mode Temperature Set Viper1 Viper 2 Mode DEFAULT VALUES There are no constant power up default values for Time To Run Temperature and Power Instead the power supply stores the last valid values it knew before the run command was issued These values are stored in the on board non volatile memory and are retrieved on power up and used as power up defaults If the power supply has never run no valid values stored in the non volatile memory then the power supply will use the following values for the power up defaults Temp 500 C Time To Run OmSec Power OW Once again the parameter values are written to the non volatile memory after Run command is issued If the user entered new valid values and then turned the power supply off without sending the Run command then those values will be forgotten on the next power up and previously stored values will be used instead VALID PARAMETERS Every time that the new value for Time To Run Temperature or Power is sent to the power supply that value is tested to be within the valid range If the new value is found to be outside of the valid range then it s ignored and the most recent successfully entered value will be used instead The valid range for the parameters is 02012 High Frequency Power LLC dba iTherm Technologies Page 18 of 31 A special comment on the po
21. er supply simply insert the 2 prongs into the HF connector with the keyed channel in the up position and turn the outer ring turn clockwise until it locks into position Follow the opposite procedure for removal of the coil The power supply will automatically adjust to every coil connected ALWAYS ENSURE THAT THE POWER SUPPLY IS POWERED OFF BY MOVING THE ROCKER SWITCH ON THE REAR PANEL TO THE OFF POSITION BEFORE CONNECTING OR DISCONNECTING A COIL MODES OF OPERATION This unit supports three modes of operation Time Mode Power Mode and Temperature Mode To cycle between modes simply press the mode button on the front panel until the desired mode is reached cycling between modes is not permitted while the power supply is running In each mode the LEDs on the front panel indicate the status of the power supply Green indicates that the unit is running yellow indicates that the unit is in standby and red indicates that there is an error Please consult the TROUBLESHOOTING section on page 15 if an error occurs NoTE Custom run modes are available please contact iTherm Technologies for details if alternate configurations are required DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE WORK PIECE FROM THE COIL WHILE POWER IS RUNNING OR DRY FIRE THE COIL CYCLE POWER WITHOUT THE WORK PIECE PLACED IN THE COIL DOING SO CAN POTENTIALLY DAMAGE THE EQUIPMENT AND MAY VOID YOUR WARRANTY 02012 High Frequency Power LLC dba iTherm Technologie
22. etting is wrapped around to 0 The host will send a 6 byte message The first byte is the character f bytes 2 5 is the timer set point with LSB in byte 2 and MSB in byte 5 The sixth byte is the checksum The power supply will echo back the command If an invalid set point is transmitted the power supply will reply with the set point it is going to use The reply construction is identical to the command instruction To set the time set point the host will send 0x66 OxE8 0x03 0x00 0x00 0x51 The power supply will reply with 0x66 OxE8 0x03 0x00 0x00 0x51 In the example we have configured the set point to 1 000ms Start h Turns the power supply on in the present set mode The host will send a 2 byte message The first byte is the character h and the second byte is the checksum The power supply will echo back the command To start the power supply the host will send 0x68 0x68 The power supply will reply with 0x68 0x68 Stop i Turns off the RF output The host will send a 2 byte message The first byte is the character i and the second byte is the checksum The power supply will echo back the command To stop the power supply the host will send 0x69 0x69 The power supply will reply with 0x69 0x69 Change to temperature mode j When issued before run command this command switches the power supply to temperature mode The command has no effect if issued while the power supply is running the power sup
23. fifth byte is the checksum To request the current temperature set point the host will send 0x62 0x62 The power supply will reply with 0x62 0x03 OxDO 0x07 0x3C Decomposing the message we get the set point for the example is 500 0 C Get Time To Run e Returns the current timer set point in milliseconds The host will send a 2 byte message The first byte is the character e and the second byte is the checksum The power supply will reply with a 7 byte message The first byte is an echo of the e the second byte is the number of bytes remaining in the message including the checksum 0x05 Bytes 3 6 are a double word containing the timer set point with the LSB in byte 3 and MSB in byte 6 The last byte is the checksum Page 21 of 31 Example Command Character Description Valid Range Construction Reply Example Command Character Description Construction Reply Example Command Character Description Construction Reply Example Command Character Description 02012 High Frequency Power LLC dba iTherm Technologies To request the current timer set point the host will send 0x65 0x65 The power supply will reply with 0x65 0x05 OxE8 0x03 0x00 0x00 0x55 Decomposing the message we get the set point for the example is 1000ms Set Time To Run f Configures the timer set point in milliseconds 0 1 800 000ms If the parameter is set above 1 800 000ms then the temp s
24. g Factor N A The host will send a 2 byte message The first byte is the character T and the second byte is the checksum The power supply will send 7 byte message The 15 byte is an echo of the T the 2 9 byte is the number of bytes remaining in the message 0x05 including the checksum the 3 6th bytes are a 32 bit float representing the scaling factor and 7 byte is the checksum To request the line voltage scaling factor the host will send 0x54 0x54 If the scaling factor is equal to 1 0 the power supply will reply with 0x 54 0x05 0x00 0x00 0x80 Ox3F 0x18 Set Power Scaling Factor U capital U Sets Power scaling factor 0 0 to 10 0 The host will send a 6 byte message The first byte is the character U the 2rd 5th bytes are a 32 bit float representing the pulse scaling factor and 6th byte is the checksum The power supply will echo back the command The reply construction is identical to the command construction Page 29 of 31 Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply Example 02012 High Frequency Power LLC dba iTherm Technologies To set the scaling factor to 1 0 the host will send 0x55 0x00 0x00 0x80 Ox3F 0x14 The power supply will reply with 0x55 0x00 0x00 0x80 Ox3F 0x14 Get Line Voltage V capital Returns Line
25. have reached their maximum permissible operating limit The power supply will not operate until the power supply has cooled to an acceptable temperature Power is not reaching the unit or the unit is off Partial reset of microcontroller Partial reset of microcontroller 02012 High Frequency Power LLC dba iTherm Technologies Check coil connection and coil continuity Replace coil if faulty Consider adding removing turns or using a different coil Check the coil for damage Check fans for operation Check air filters clean if needed Reduce power settings or duty cycle Move power supply to a cooler environment Disconnect power and check source voltage Check fuse replace if needed Cycle mains power reboot the machine Cycle mains power reboot the machine Page 15 of 31 INCLUDED IN SHIPMENT NEMA 6 20 240V mains plug qty 1 Plug Receptacle I O pin connectors keyed qty 2 This manual qty 1 HHH THERM For 24 Hour Technical Support Call 1 800 332 1111 Set Tine 3324 HIG 1 4 Power Supply User s Manual 2012 High Frequency Power LLC dba iTherm Technologies Page 16 of 31 APPENDIX A SERIAL PORT COMMAND LIST HosT COMPUTER SETTINGS To communicate with the RS 232 port on the power supply the following settings are necessary BAUD RATE 115200 DATA BITs 8 STOP BITS 1 PARITY None CH
26. he power supply will reply with Ox4B 0x00 0x00 0x80 Ox3F 0x04 0x00 OxOE Get PID parameters 4 Returns proportional integral and derivative coefficients N A The host will send a 2 byte message The first byte is the character L and the second byte is the checksum L The power supply will send a 15 byte message The 15 byte 15 an echo of the L the 2 byte is the number of bytes remaining in the message 0x0D including checksum the 3 4 6t bytes are a float representing proportional coefficient LSByte first 7 109 bytes are a float representing the integral coefficient LSByte first the 11 14 bytes are a float representing the derivative coefficient LSByte first and the 15th byte is the checksum 02012 High Frequency Power LLC dba iTherm Technologies Page 26 of 31 Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction 02012 High Frequency Power LLC dba iTherm Technologies To request the PID parameters the host will send 4 0x4C If all coefficients are 1 0 then the power supply will reply with 0x4C 0 0 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F 0x96 Decomposing the message we get proportional coefficient integral coefficient derivative c
27. l resistance of the material can have a large effect on how much heat is generated from the opposition to the flow of eddy currents within the material THERMAL MASS Large pieces will take longer to heat than smaller pieces of the same material Parasitic losses can occur as a result of application parameters such as O PARTS PLACEMENT Improper placement of the work piece within the coil or large air gaps between the coil flux concentrator and work piece decreases magnetic coupling levels hence decreasing performance ADJACENT COUPLING Metal fixturing within close proximity of the coil head or coil leads can respond inductively This is especially true if the fixturing material has a higher permeability than the work piece In addition to potentially heating up adjacent coupling will also decrease the efficiency of heating the work piece THERMAL CONDUCTION Thermally conductive fixturing in direct contact with the work piece or small active heating areas on larger work pieces can act as heat sinks potentially increasing cycle time Operating frequency can have an effect on heating response times in some applications Operating frequency is dependent upon coil and load characteristics Please contact iTherm for alternative coil configurations if a specific frequency response is required 2012 High Frequency Power LLC dba iTherm Technologies Page 7 of 31 INTERFACE F i133khz P 37 SW Wid COM C D E G
28. nal feedback system is an ungrounded K type thermocouple or infrared thermocouple with K type output connected to pins 1 amp 2 or 3 amp 4 see INPUT OUTPUT 1 0 CONNECTORS on page 12 To use temperature mode Press the mode button until temperature mode is reached Use the T and 4 arrows to enter the desired final temperature To toggle between C or F quickly press and release the T and arrows simultaneously 3 Once the desired temperature set point is entered push the 1 0 button to start the flow of power to the coil 4 Push I O button again to stop the flow of power to the coil NorE Custom options are available if a different temperature feedback system is required Please contact iTherm Technologies for more information if a different feedback loop is necessary IF THE ACTUAL TEMP IS AT OR ABOVE THE SET TEMP ON THE LCD POWER WILL NOT BE FLOWING THROUGH THE EVEN IF THE GREEN LED IS ILLUMINATED DO NOT MISTAKE THIS CONDITION WITH THAT OF STANDBY AS POWER WILL AUTOMATICALLY BEGIN TO FLOW ONCE AGAIN WHEN THE ACTUAL TEMPERATURE DROPS BELOW THE SET TEMPERATURE IF A STANDBY CONDITION IS INSTEAD DESIRED PRESS THE I O BUTTON ONCE TO STOP AUTOMATIC TEMPERATURE MODULATION AND VERIFY THAT THE YELLOW LED IS ILLUMINATED ANALOG MODE Analog mode is a non standard feature available on all HIG 1 4 power supplies Analog mode offers the operator a way to control the power or temperature set point in real time in thei
29. not running 1 is running Yellow LED 0 off 1 on in Power Off Can be ignored 6 Red LED 0 off 1 on Can be ignored Temperature Units 1 C 0 F Not Used Error Bits 0x0400 0b0000010000000000 0 Corrupted configuration structure EEProm 3 No Load Connected 5 Circuit Breaker Tripped note no CB in NxThera Unit 7 Control Board Overheat 5 jj 7 ThermaFuselTrp gt S 8 ThermalFuse2Trip gt Z S 9 Thermocouple 1 disconnected 1 1 10 Notusedwilalwysbel 0 0 0000 11 Setpowergreaterthan maximum power 12 InvdidLoad 43 10 11 12 Invalid Load 13 Not used 14 No errors being reported in example Command Get Thermocouple gain and offset Character J 02012 High Frequency Power LLC dba iTherm Technologies Page 25 of 31 Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply Returns the thermocouple gain and offset N A The host will send a 2 byte message The first byte is the character and the second byte is the checksum J The power supply will send a 9 byte message The first byte is an echo of the the second byte 15 the number of bytes remaining in the message 0x07 including the checksum the next four bytes
30. o indicate that the power supply is either not ready to process commands turned off or coming out of reset or the serial interface is not working due to a hardware issue If the Host PC were to communicate with the power supply by sending any other command for example a two byte Get Current Status command string pp then a situation might arise when the power supply comes out of reset after the first character of the two byte sequence has been sent As a result the power supply would only receive the second byte of the two byte command string and thus the command data protocol will be out of sync with the power supply waiting for the second character of the two byte string The host will send a 1 byte message The message will be only the o character The power supply will respond a one byte message of To request the current temperature set point the host will send Ox6f The power supply will reply with Ox21 Set Power A 2012 High Frequency Power LLC dba iTherm Technologies Page 23 of 31 Description Valid Range Construction Reply Example Command Character Description Construction Reply Example Command Character Description Construction Reply Example Command Character Description Construction 02012 High Frequency Power LLC dba iTherm Technologies The set power command configures the power set point with a resolution of 1 watt 0 300W
31. o s3 hex and 16 Bit Flash Programmer exe 2 Right click on boot bat select edit and change to whichever port you are using for RS 232 communication If you are unsure of the port number it can be obtained in the device manager Save and close the file 3 Make sure the RS 232 cable is connected to both the power supply and to the computer or USB adapter s serial port and that the power supply is off 4 While holding down the I O button turn the power supply on Leave I O held for at least 3 seconds the LCD screen on the power supply should be blank 5 Release the I O button and double click on boot bat A DOS window should open indicating that the power supply is being reprogrammed Wait for it to finish the window should close automatically This will take roughly 30 seconds 6 Unplug the RS 232 cable and restart the power supply the version number should indicate the change or the custom setup should now be enabled ONCE THE HOST COMPUTER HAS ESTABLISHED COMMUNICATION WITH THE POWER SUPPLY THE UNIT CANNNOT BE CONTROLLED OR TRIGGERED UN TRIGGERED BY THE FRONT PANLE OR 1 PINS TRIGGERING EXTERNALLY DEACTIVATES THE BUTTONS ON THE FRONT PANEL TO USE THE FRONT PANEL OR PINS AGAIN YOU MUST FIRST COMMUNICATION WITH THE POWER SUPPLY AND HOST COMPUTER 02012 High Frequency Power LLC dba iTherm Technologies Page 13 of 31 MAINTENANCE All iTherm power supplies come equipped with an intelligent load detect syst
32. ode 4 5th bytes are an unsigned short representing the pulse length in usec and 6 byte is the checksum To request the mode the host will send 0x50 0x50 If the power supply is in Viper 1 mode of operation and pulse length 100us then the power supply will reply with 0x50 0x04 0x01 0x64 0x00 OxB9 Decomposing the message we get Viper 1 with the pulse length 100us NOTE If the power supply is in Viper 2 mode of operation then the host should ignore the pulse length field as it is irrelevant Set Viper1 Viper 2 mode Q Sets Viper 1 vs Viper 2 mode of operation and pulse length to be used when operating in Viper 1 mode This command is ignored if sent while the power supply is running Mode character 1 or 2 The host will send a 5 byte message The first byte is the character Q the 2rd byte 0x01 for Viper 1 mode or 0x02 for Viper2 mode the 319 4th bytes are an unsigned short representing the pulse length in usec and the 5th byte is the checksum The power supply will echo back the command The reply construction is identical to the command construction To set the Viper 1 mode with pulse length lt 1005 the host will send 0x51 0x01 0x64 0x00 OxB6 The power supply will reply with 0x51 0x01 0x64 0x00 OxB6 Get Line Voltage Scaling Factor R Returns Line Voltage Scaling Factor N A Page 28 of 31 Construction Reply Example Command Character Description Valid Range Cons
33. oefficient 1 0 Set PID parameters Sets PID parameters N A The host will send a 14 byte message The first byte is the character M the 224 5th bytes are a float representing the proportional coefficient LSByte first 6th 9 bytes are a float representing the integral coefficient LSByte first the 10 139 bytes are a float representing the derivative coefficient LSByte first and the 14 byte is the checksum The power supply will echo back the command The reply construction is identical to the command construction To set the proportional integral derivative coefficient to 1 0 the host will send Ox4D 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F Ox8A The power supply will reply with Ox4D 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F 0x00 0x00 0x80 Ox3F Ox8A Get output modulation frequency N Returns the output modulation frequency in Hz N A The host will send a 2 byte message The first byte is the character N and the second byte is the checksum N The power supply will send 4 byte message The 15 byte is an echo of the N 224 byte is the number of bytes remaining in the message 0x02 including the checksum the 3rd byte is an unsigned char representing the output modulation frequency in Hz and 4 byte is the checksum To request the output modulation frequency the host will send Ox4E Ox4E If output modulation frequency is equal to 16 Hz then
34. ply would echo back the Page 22 of 31 Construction Reply Example Command Character Description Construction Reply Example Command Character Description Construction Reply Example Command Character current mode The host will send a 2 byte message The first byte is the character j and the second byte is the checksum The power supply will echo back the current mode with checksum To change to temperature mode the host will send 0x6A 0x64 The power supply will reply with 0x6A Change to time mode k When issued before Run command this command switches the power supply to time mode The command has no effect if issued while the power supply is running the power supply would echo back the current mode The host will send a 2 byte message The first byte is the character k and the second byte is the checksum The power supply will echo back the current mode with checksum To change to time mode the host will send Ox6B Ox6B The power supply will reply with Ox6B Ox6B Handshake It is highly recommended that the handshake command be used when establishing communication with the power supply Being a single byte command it s guaranteed to be processed correctly once received When establishing communication with the power supply the Host PC should stay in a loop sending the handshake command and waiting for a response No response is likely t
35. r corresponding modes using a 0 5 volt DC signal connected to 1 0 pins 3 amp 4 on the rear panel Enablement of this mode disables the temperature feedback capability of these two 1 0 pins I O pins 1 amp 2 can still be used for temperature mode feedback Please contact iTherm Technologies prior to ordering your power supply if you desire to have analog mode capability enabled Existing power supplies can always be returned to iTherm in the future if the decision is made to retrofit the unit with analog mode capability 02012 High Frequency Power LLC dba iTherm Technologies Page 11 of 31 EXTERNAL COMMUNICATION INPUT OUTPUT I O CONNECTORS Communicating externally with the power supply is most easily accomplished using the green I O connectors numbered 1 through 8 on the rear panel To physically connect to this interface push on the orange tab above the wire insert on the connector plug and insert the stripped end of the communication wire into the corresponding wire hole and release the tab When all necessary wires are installed insert the connector plug into the correct set of keyed 1 0 ports The functionality of each of the 8 I O pins is as follows Pins 182 Pins3 amp 4 Pins 5 amp 6 Pins 7 amp 8 These pins serve as the primary thermocouple feedback input required for closed loop operation of temperature mode or temperature monitoring in power mode Only K Type thermocouples are compatible with these por
36. s Page 9 of 31 PowER MODE The top line of LCD will display Set Power to indicate when the unit is in power mode Power mode operates in open loop control such that a user specified power setting runs continuously until the power supply is prompted to stop To use power mode Set the unit to the desired power output level using T and lt arrows Once the desired set point is achieved press the I O button to deliver power to the coil Note that while the machine is running the operator is free to use the T and 4 arrows to deliver more or less power in real time to the coil 3 To stop the flow of power to the coil simply presses the I O button once more NOTE If more power is requested of the power supply than the power supply is able to deliver into that part for reasons specified in the IMPORTANT APPLICATION CONSIDERATIONS on page 7 the power supply will automatically calibrate itself and run at the maximum allowable power once the I O button is pressed In this scenario the power supply operator will not be able to increase the output power setting MODE The top line of the LCD will display Set Time to indicate when the unit is in time mode Time mode operates much like power mode but in closed loop control such that the user specifies a runtime setting in addition to the already specified power setting To use time mode Enter power mode and set the desired power output setting using the T and arrows Once
37. terlocks or unit grounding iTherm Technologies provides information on its products and associated hazards but assumes no responsibility for the after sale operation of the equipment or the safety practices of the owner or user SYMBOLS USED IN THIS MANUAL This symbol indicates a potential safety hazard to personnel or property This symbol indicates a warning that requires special attention To ensure years of dependable service all iTherm Technologies products are thoroughly tested prior to shipment All parts and labor on the unit described herein carry iTherm s standard 1 year warranty Additional information about the Terms and Conditions of Sale are listed in the quotation sent by iTherm to your procurement office THERE ARE NO USER SERVICEABLE PARTS IN THIS POWER SUPPLY OPENING THIS UNIT MAY VOID YOUR WARRANTY CALL ITHERM IF YOU HAVE ANY QUESTIONS ABOUT OUR PRODUCTS OR IF YOU REQUIRE ANY ASSISTANCE TROUBLESHOOTING ALL CUSTOMER SUPPORT CALLS ARE OFFERED TO OUR CUSTOMERS AT NO CHARGE 2012 High Frequency Power LLC dba iTherm Technologies Page 3 of 31 RETURNING UNITS FOR REPAIR Prior to returning any unit for repair or replacement please contact iTherm Technologies In many cases the problem can be resolved remotely without a need to return the unit customer service inquiries are available free of charge Please be prepared to provide the serial number of the unit and a detailed description of the problem
38. truction Reply Example Command Character Description Valid Range Construction Reply Example Command Character Description Valid Range Construction Reply 02012 High Frequency Power LLC dba iTherm Technologies The host will send a 2 byte message The first byte is the character R and the second byte is the checksum R The power supply will send a 7 byte message The 15 byte is an echo of the R the 219 byte is the number of bytes remaining in the message 0x05 including checksum the 3 6th bytes are a 32 bit float representing the scaling factor and 7 byte is the checksum To request the line voltage scaling factor the host will send 0x52 0x52 If the scaling factor is equal to 1 0 the power supply will reply with 52 0x05 0x00 0x00 0x80 0x16 Set Line Voltage Scaling Factor S capital 5 Sets Line Voltage scaling factor 0 0 to 10 0 The host will send a 6 byte message The first byte is the character S the 2rd 5th bytes are a 32 bit float representing the pulse scaling factor and the 6th byte is the checksum The power supply will echo back the command The reply construction is identical to the command construction To set the scaling factor to 1 0 the host will send 0x53 0x00 0x00 0x80 0x12 The power supply will reply with 0x53 0x00 0x00 0x80 Ox3F 0x12 Get Power Scaling Factor ep Returns Power Scalin
39. ts Pin 1 is used for the positive lead and pin 2 is used for the negative lead for North American style coloring the yellow represents the lead and red represents the lead These pins serve as the secondary backup pins for use with thermocouple feedback As with pins 1 amp 2 only K type thermocouples are compatible Pin 3 is used for the positive lead and pin 2 is used for the negative lead NOTE These pins can be substituted for Analog Mode inputs page 11 Contact iTherm Technologies if you require analog mode capability for your application These pins provide a normally open safety relay for monitoring that closes when current is flowing through the coil This usually occurs when the power supply is running but will also occur during the load detect cycle that produces an invalid load error as a result of the load detection system current These pins provide an external trigger such as a PLC or foot pedal for activating or deactivating the programmed event when pin 7 is shorted to pin 8 This is analogous to pressing the I O button on the front NOTE This functionality is edge triggered in time and temperature mode trigger once to start the cycle re trigger once more to stop the cycle and level triggered in power mode power only flows so long as the short is maintained releasing the trigger stops the flow of power to the coil ONCE THE POWER SUPPLY HAS BEEN TRIGGERED USING THE I O PINS IT CAN ONLY BE U
40. wer setting When in Viper2 mode of operation every time the power supply is commanded to run it goes through the load identification phase and determines the maximum power setting it is capable of applying to that load If the power supply is commanded to run at a higher setting than is possible for that load it will run at the maximum possible power setting that was determined during the load identification phase COMMAND LIST COMMAND SetTempC GetTempC GetTimeToRun mSec SetTimeToRun mSec Start Stop ModeTemp ModeTime Handshake GetCurrentStatus Set Power Get Power Mode Power Get TC Gain and Offset Set TC Gain and Offset Get PID Parameters COMMAND CHARACTER COMMAND DATA BYTES NOT COUNTING COMMAND CHARACTER amp CHECKSUM 1int 2 bytes 2 0 unsigned long int 4 bytes mSec 0 0 0 0 0 0 unsigned int 2 bytes Watts 0 Gain float Offset short 6 bytes 0 02012 High Frequency Power LLC dba iTherm Technologies RESPONSE Echo 1 int 2 bytes unsigned long int 4 bytes mSec Echo Echo Echo Echo Echo 1 byte CurrentStatusStruct Echo unsigned int 2 bytes Watts Echo Gain float Offset short 6 bytes Echo Three floats 212 bytes ECHO Yes No No Yes Yes Yes Yes Yes Page 19 of 31 COMMAND Set PID Parameters
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