NEOTHERM 70 EVO - 60V Manual - P1600 PDF

NEOTHERM 70 EVO 70kVA 60V
Instruction and operating manual

Model Number:

Manufactured in ITALY

Serial Number
NTE/W-R/12/70/60/XXXX
Ref: NEOTHERM 70 EVO W-REC (70kVA 60V), MANUAL

Issued: 09/12/2012

SICORT HEAT TREATMENT SERVICES s.r.l.
Loc. Castione Marchesi, 268/b 43036 Fidenza (PR) ITALY
Tel. +39-0524-67800 Fax +39-0524-67288 E-mail [email protected]
2

CONTENTS

Chapter Page

Specifications 3
Introduction 4
Functions 5
Pre commissioning checks 6
Installation and commissioning 7
General operation of components 8-9
General operating instructions 10-11
Temperature controller operating instructions 12-13
Maintenance 14
Fault finding 14
Ordering replacement parts and spares 15
Replacement parts list 16-22
Warranty 23

Date of issue J anuary 2012
2010 Sicort

All rights reserved. No part of this document may be reproduced, stored in retrieval system, or transmitted in
any form by any means, electronic, mechanical, photocopying, recording or otherwise without the prior,
written permission of Sicort.

Issued: 09/12/2012

3

SPECIFICATIONS

This unit features a 70 kVA, 3-phase, forced air cooled, double wound Class H insulated, dry type, power
transformer suitable for use in ambient temperatures not exceeding 40 Deg. C. and having a tapped mesh
(delta) primary winding suitable for connection to a 50/60 Hz supply.

The secondary winding is Y (star) connected, with the neutral point grounded (earthed), to provide a safe
phase to neutral voltage for heating power.

Over-temperature protection of the transformer is by means of three sealed miniature (normally closed)
thermostats, embedded in the windings of the transformer.

The main isolation switch is a 80 A triple pole molded case circuit breaker with magnetic and shunt trips for
transformer thermal protection.

Rating : 70 kVA

Frequency : 50/60 Hz

Primary Volts : 380/400V 3-Phase

Primary Amps : 380V Primary : 106A
:
Secondary Open Circuit Voltage: 65V (Factory Setting)
Exclusively for use with 60V heating elements

Secondary Current : 360A Per Phase

Duty Cycle Rating : 100%

Two 110V, 5A Auxiliary Outlets are fitted as standard to the unit.

EC declaration of conformity available upon request.

(See contact details on page 13)


Issued: 09/12/2012

4

INTRODUCTION

The parameters appertaining to post weld heat treatment are clearly defined in the appropriate USA, British
and European Standards. Postweld heat treatment to these codes may be affected by electrical resistance
methods and the following represents the fundamental requirements for effective heat treatment.

The system must be fully capable of reaching and correctly recording the specific temperatures.

Heating conditions must allow for various component thicknesses such that uniform temperatures result.
Special provision often has to be made to control temperature gradients away from a heated zone in
order to minimize additional stress.

The operation has to be recorded and controlled within the limits of specification.

The oil refinery, petrochemical and power plant industries all utilise vast quantities of tubing and pipework, a
substantial proportion of which has a preheat and/or postweld heat treatment requirement and this can be
successfully achieved by the use of Sicort Heat Treatment, Power Source Units.

Sicort equipment is manufactured to the highest European standards. The design is based upon the results
of third party testing for compliance with European Safety Directives and Sicorts extensive experience in the
field of heat treatment engineering.

The new Sicort Neotherm 70 EVO 70kVA, 6 output, heat treatment power source has been developed to
meet the real needs of the heat treatment engineering industry. Our design is based on almost 50 years
experience as the worldwide market leader in the field of heat treatment.


Issued: 09/12/2012

5

FUNCTIONS


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6

PRE COMMISSIONING CHECKS

You should ensure that an electrically competent person carries out the pre-commissioning checks.

Check:-

IMPORTANT! That the primary transformer tapings are set to the correct voltage for the
supply you are using. Unless the customer specifies otherwise the 70kVA power source is
dispatched with the transformer primary tapping links set for an incoming supply of 380V.

General condition of the transformer.

With panels removed check all connections are tight as vibration during shipment may cause some
slackening which could result in overheating and failure during normal service.

The tapping board and transformer windings are dry.

Measure insulation resistance of primary winding to ground by means of a 500V insulation tester
(megger). Minimum insulation resistance to ground at 20C ambient should be not less than 10
Mega Ohms. Contact Sicort for drying out instructions if lower values are measured. For warranty
purpose, it is important that your electrical inspector records the primary winding As new
insulation resistance measurements either in this manual or in your own equipment records
date of the test.


Issued: 09/12/2012

7

INSTALLATION AND COMMISSIONING

You should ensure that an electrically competent person carries out installation and commissioning
of the Power Source.

WARNING
To prevent contact with hazardous voltages inside the Power Source
Unit, which may result in electrical shock or burns, never carry out any
work inside the Power Source Unit until the unit has been isolated
from the incoming supply.

This Power Source is designed for general usage. However, as use on construction sites exposes
electrical equipment, to damage from falling objects and the general movement of steelwork on the site,
it is preferable to place the Power Source in a protected position. Also protect the equipment from
adverse weather conditions and, in tropical situations, from the direct effects of the sun, as overheating
could result under normal loading conditions.

Connect a 380V 3-Phase and earth primary power supply to the supply input terminals which are
accessed by removing the back panel from the power source and are located inside the unit on the left
hand side of the base of the power source . Current rating of the supply conductors shall not be less
than the rated primary current for the connected supply voltage (see Specifications on page 3) and of
sufficient size to limit the voltage drop to a value permissible for the satisfactory performance of the
Power Source.

Check incoming power supply for correct voltage between phases and, if necessary, adjust primary
tapings on the Power Source transformer to suit.

Earthing (grounding) of the Power Source should be carried out to the requirements of the local National
standards.

Ensure that suitable HRC fuses or excess-current circuit breaker at your supply distribution point
properly protects your service conductor and the Power Source.

Once the pre-commissioning checks have been satisfactorily completed, the supply and earth
conductors have been connected and the panels have been replaced the incoming supply can be
energised. The Power Source unit can then be energised by switching the 80A circuit breaker (isolator)
to the ON position.

Connect a wire link between the positive and negative pins in six thermocouple plugs and insert one into
each thermocouple socket. This is completely safe, as the thermocouple sockets are not connected to
an electrical supply. Shorting out the thermocouple sockets will cause the temperature controllers to
receive a signal equivalent to the ambient air temperature.

Set the temperature controller so that the control temperature is set to a temperature above the ambient
air temperature (for example 100C).

For each output, use an a.c. voltage test meter to measure the voltage between each 60V output
camlock socket and 0V camlock socket. Readings of approximately 60V volts should be obtained. Next,
for each output channel in turn, connect the voltage test meter between the 60V output camlock socket
and 60V camlock socket. Readings of approximately 60V should be obtained.

WARNING
Caution should be used whilst taking the measurements, as 60V a.c.
will be present between output sockets on each Channel.

Upon completion of the foregoing test procedures, switch off the Power Source Unit by switching off the
60A circuit breaker.

Issued: 09/12/2012

8

GENERAL OPERATION OF COMPONENTS

OVERVIEW

Each control channel has its own temperature controller, which requires a thermocouple transducer for
automatically controlling the workpiece temperature within close limits. Paired thermocouple sockets are
provided on each channel to receive a mV signal from the thermocouple in the hot control zone on the workpiece
and, if necessary, to allow a parallel connection to a temperature recorder.

The thermocouple extension cables from the workpiece to the programmer are plugged into the thermocouple
input sockets and if necessary linked out to a temperature recorder. The recorder may be powered from the
110V auxiliary supply sockets located on the rear panel of the Power Source Unit.

The output power for the heaters is by connection via feed and return cables to the 60V output and the 0V output
camlock sockets.

OUTPUT CONNECTIONS FOR USE WITH 60V HEATING ELEMENTS


Issued: 09/12/2012

9

SOLID STATE RELAY (SSR)

The SSR is an electronic switching device in which a small control signal controls a larger load current or voltage.
It comprises a voltage or current sensor which responds to an appropriate input (control signal), a solid-state
electronic switching device of some kind which switches power to the load circuitry either on or off, and some
coupling mechanism to enable the control signal to activate this switch without mechanical parts. The relay may
be designed to switch either AC or DC to the load. It serves the same function as an electromechanical relay, but
has no moving parts.

ADVANTAGES OVER MECHANICAL RELAYS
Most of the relative advantages of solid state and electromechanical relays are common to all solid-state as
against electromechanical devices.
SSRs are faster than electromechanical relays; their switching time is dependent on the time needed to
power the LED on and off, of the order of microseconds to milliseconds.
Lower (if any) minimum output current (latching current) required.
Increased lifetime, particularly if activated many times, as there are no moving parts to wear
Output resistance remains constant regardless of amount of use.
Clean, bounceless operation.
Decreased electrical noise when switching.
No sparking, allowing use in explosive environments where it is critical that no spark is generated during
switching.
Totally silent operation.
Inherently smaller than a mechanical relay of similar specification (if desired may have the same "casing"
form factor for interchangeability).
Much less sensitive to storage and operating environment factors such as mechanical shock, vibration,
humidity, and external magnetic fields.

TEMPERATURE CONTROLLERS

When in Programmer mode, the temperature controller program is entered by means of the of the three facia
buttons. The Temperature controller will, via the contactors, control the heating elements and maintain the
temperature of the workpiece thermocouple at the temperature, which has been set. Full instructions for the
temperature controller are included in this manual.

THERMOCOUPLES

It is of the utmost importance that the polarity of the thermocouple and the compensating cable (thermocouple
extension) is connected correctly, as incorrect polarity may result in over heating of the workpiece during the
heat treatment.

The two pin polarised plugs and sockets are identified positive/negative with the large pin negative. Always use
the special connectors for thermocouple circuits and no other types.

Type K, thermocouple wire, as normally supplied by Sicort is of twisted pair pattern with one wire coloured red
(+) and one wire coloured green (-).

Caution: To avoid serious damage to electronic temperature controlling and recording instruments,
thermocouples must be disconnected from the unit whilst using a capacitance discharge unit (thermocouple
attachment unit TAU) to affix the thermocouple wire to the workpiece.


Issued: 09/12/2012

10

GENERAL OPERATING INSTRUCTIONS

CONTROL ZONES

When using a 70kVA, 60V, 6-way (6-channel or 6-output) Power Source for either preheating or post weld
heat treatment, the Ceramic Pad Heaters are connected in groups of 1, 2, 3 or 4 per control channel
(output).If there is more than one heater in a heater control group, the heaters in the control group are
connected together in parralel across one of the output channels of the 70kVA power source. (see example
diagram below)


Issued: 09/12/2012

11
As shown in the diagram, 60V heating elements are connected, using splitters where nessessary, into
groups of one, two or three heaters. The heater groups are then connected to the power source across
the 60V and 0V output sockets on each channel.

The control thermocouple for each group of heaters is connected to a compensating lead which is in turn
connected to a thermocouple input socket on the power source, temperature controller or programmer
unit. Ensuring that the channel corresponds to the output supply channel associated with that control
thermocouple. i.e. thermocouple connected to channel one thermocouple input with channel one output
supply camlocks.

If a temperature recorder is being used to record the preheat then a thermocouple compensating cable
link will be connected from the second of each pair of thermocople socket inputs on the power source,
temperature controller or programmer unit to the corressponding thermocouple input socket on the
temperature recorder. i.e. thermocouple input channel number one on power source, temperature
controller or programmer unit to thermocouple input channel number one on the temperature chart
recorder.

Connect a 110V supply, from a 110V auxillary output on the power source, to any recorders or separate
temperature controller or programmer units being used

Connect the power source 3 phase and earth supply plug to an appropiate 3 phase and earth supply
output socket.

WARNING
Do not remove the 3 phase plug or attempt to make a hard wire
connection to a 3 phase connection box, fuse board or generator etc.
unless you have been trained, qualified and authorised to do.

Energise the Power Source Unit using the 125A circuit breaker.

Switch all controllers ON.

Set all controllers to programmable control mode.

Switch those required to control only mode

Enter programs in temperature controllers

The temperarure controllers will energise the contactors as nessessary to apply sufficient heating power
to each zone of heaters to achive and maintain the set temperature.


Issued: 09/12/2012

12

1600P PROGRAMMER OPERATING INSTRUCTIONS

Note: Data for the thermal cycle execution can be entered only when the programmer is STOPPED
(PRG led off)

The programmer function allows carrying out a program as a set of steps each made of two segments:

a ramp and a permanence.

Each step is characterised by a set of data:

SP.S: a set-point value.
rP.t: ramp time 0,0 to 99h-59min(times base h.m.)
So.t: permanence time 0,0 to 99h-59min(times base h.m.)

Globally 8 program steps are available (0!7), making up a maximum of 4 programs, such as: 1 program
made of 8 steps, or 4 programs made of 2 steps, or 2 programs made of 4 steps etc
To access the programming parameters menu hold down the F key
- the following parameters are displayed in sequence: INFO-dAtA-ProG-StEP-CFG-InP-Out-PaSS.

Select StEP and release the F key.
Pressing once more the F key: SP.S-rP.t-So.t


Issued: 09/12/2012

13

To avoid setting errors the thermal cycle should be always drawn, as indicated in the example below:

didascalia
Time in hours and minutes
Indicate the values in the table

The values set for the programming steps are automatically stored each time the F key the is pressed

To quit any menu or end of programming hold down the F key.

The * key on the front panel of the programmer allows resetting the tool without using external contacts and
then restarting with a new program.

-press the * key: the AUX led switches on
- press the * key again: the AUX led switches off (the system goes back to the StEP 0 cycle start set value)

The key (circle with dot) on the front panel of the programmer allows to Start/Stop
the selected thermal cycle:
-program to Start with PRG led on, to Stop with led off.

The bargraph indicates the deviation of the input variable (Tc) from the set-point of the program
(10%....+10% f.s).

For further major details see the GEFRAN original manual enclosed


Issued: 09/12/2012

14
MAINTENANCE

WARNING
To prevent contact with hazardous voltages inside the Power Source
Unit, which may result in electrical shock or burns, never carry out any
work inside the Power Source Unit until the unit has been isolated
from the incoming supply.

All electrical apparatus in constant use, particularly that subject to cyclic loading, must receive regular
maintenance inspection in order to maintain trouble-free operation.

The frequency of inspection will depend upon the operating conditions and the length of time that the
equipment is in use. Under average conditions, inspections should be made every month to ensure the
components are operating correctly, contacts are in good condition, camlock sockets are free from the
effects of over-heating or arcing, due to improper locking of the plugs and that there is no visible sign of a
fault developing.

Inadequate attention to the connectors fitted to the heating units can only result in service difficulties during
the heat treatment work. Contacts should be renewed before they become excessively worn and springs
replaced.

FAULT FINDING
Fault finding should always be systematic commencing with the most likely faults first, such as a blown fuse.
A visual inspection should always be made to ascertain that no obvious disconnections, broken components
or over-heated connections are visible. Always ascertain the reason for the fault and check that a similar
fault is not developing on other units.

Some possible fault symptoms and remedies are detailed below. You should also refer to the schematic
layout.

80A Circuit Breaker (MCCB) will not close.

Causes Action

Transient surge on closing switch Repeat

Overheated transformer causing thermal Allow to cool and check
tip to operate loading

Short circuit on secondary between two Remove short circuit
outlets or outlet and earth

One or more thermostats are open Allow transformer to cool,
circuit or if cool, replace
thermostats

Trip capacitor (CA) faulty Replace

MCCB shunt trip unit faulty Replace

Other problems could be experienced due to the following:-

Failure of the main supply. Check that the correct voltage is available from each outlet. Check for loose
or broken connections.

Faulty temperature controller. Before condemning a controller it is wise to check the associated circuits
as follows:-
o Thermocouple not type K or wrong compensating cable being used.

o Thermocouple not properly applied to the workpiece.

o Check all thermocouple connections, continuity and polarity.

o Check calibration of the controller.


Issued: 09/12/2012

15

ORDERING REPLACEMENT PARTS AND SPARES

When ordering any spare parts it is recommended that you refer to:-

a) Type of unit described herein.
b) Sicort Hts Works Order reference number
c) Date supplied
d) Your original order reference
e) Your organisation full name
f) Unit Serial number

All orders should be marked for the attention of Equipment Sales Department at the following address:

Sicort Heat Treatment Services srl
Localit Castione Marchesi, 268/b
43036 Fidenza (PR)
ITALY
Tel. No. +39 0524 67800
Fax No. +39 0524 67288
E-mail [email protected]

Website: www.sicort.com / www.sicort-hts.com

Issued: 09/12/2012

16
REPLACEMENT PARTS LIST

Description Part number Quantity Page / Position
1 Programmer 1600P Gefran 080-050-001 6 19 - 1
2 Main switch, front, 125A 080-001-016 1 19 - 2
3 Programmer on/off switch 080-001-017 6 19 - 3
4 Thermocouple panel socket 028-001-003 24 5 - Q, H, I
5 60A camlock panel sockets 040-003-002 12 5 - O, P
6 110V auxillary sockets 080-001-021 2 5 - N
7 70kW-65V main transformer 080-002-001 1 21 - 7
8 110V auxillary transformer 080-002-016 2 20 - and 21 - 8
9 Main cooling fans 080-001-015 2 21 - 9
10 Relay cooling fans 080-001-018 2 18 - 10 and 20 - 10
11 Solid state relay 080-030-001 2 18 - 11 and 20 -11
12 SSR fuse 080-035-001 6 17 - 12 and 20 - 12
13 SSR fuse holder 080-036-001 6 17 - 12 and 20 - 12
14 Auxillary fuses 080-035-010 8 21 - 10 and 22 - 1
15 Chino EH100-12 recorder 030-002-005 1 17 - 14 and 19 - 14
16 110V plug 080-001-022 1 Attached to recorder cable
17 Front pivoting wheel 080-060-001 2 19 - 16
18 Rear fixed wheel 080-060-002 2 19 - 17
19 Hinge set, doors 080-070-001 2 19 - 18
20 Hinge set, instrument protection panel 080-070-002 1 19 - 19


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23

WARRANTY

The specific unit supplied under this contract should be identified by Model Number and Serial Number in all
correspondence with Sicort.

GENERAL

When Sicort equipment is properly installed and used, our warranty covers all parts for a period of twelve
months from the date of shipment against defects in material and workmanship. Our warranty and liability is
to the extent of our furnishing F.O.B. from place of manufacture, new parts for any found defective. No
damages or charges for labour and expenses in making repairs will be allowed. Any units or parts returned
to our factory (or as otherwise directed) are to be shipped freight paid. Heating cables, connections, heating
elements and other accessories forming part of our supply are subject to three months warranty only.

All parts shipped, whether to replace parts which failed within the warranty period or not, will be invoiced at full ex
works factory prices. The parts replaced should then be returned to our factory, transportation prepaid, for our
examination. Credit will be issued if our inspection indicates failure was due to defect of material or workmanship
and if failure occurred during the warranty period. No warranty consideration will be given on parts showing
evidence of tampering or disassembly.

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Instruction and operating manual

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