This section covers test procedure and start-up requirements for tho VIP system The actual procedure is usually performed by INDUCTOTHERM service engineer It is recommended that customer maintenance and operating personnel assist in this operation in order to complete. the tests quickly and gain experience in operating the unit during a melt cycle The training should quality individuals as system operators and familiarize qualified maintenance personnel with routine maintenance and service procedure .
ALL CHECKOUT AND TEST PROCEDURES, SPECIFIED IN THIS SECTION SHOULD BE ATTENDED BY MAINTENANCE PERSONNEL TRAINED BY INDUCTOTHERM OR PREFERABLY IN THE PRESENCE OF INDUCTOTHERM SERVICE ENGINEER ONLY.
(2) CONTROL POWER AND INTERLOCK CHECK
Before applying main power to the unit, the control circult should be checked. The units have internal control transformers to provide control power Some systems have independent sources of main power and auxiliary or control power To engage only the controls on a system wilh all power coming from a single main circuit breaker, it is necessary lo remove the power fuses as described below Control checks are.
1 Inspect unit for signs of loose or damaged components Re torque all bus and wiring joints Do not proceed unil all transit damage has been repaired and all connections are tightened.
2 Remove power fuses from the three phase bridge panel(s).
3 Open water shut-off valve (customer furnished).
4 Check water pressure gauge Pressure should be between 40 and 60 PSI (2.8 and 4.2 BAR) with all furnaces operating at full flow.
5 Check water temperature gauge The temperature should be below what mentioned in the name plate.
6 Check the rotation of the internal pump by -Jogging” the starter Be sure that the internal syatem reservoir is properly filled before starting the pump.
7 Check all indication of Monitor Board and interlocking system operation.
8 Place circuit breaker switch in “ON positlion The ciruit breaker can only be enabled when the doors are closed When a cabinet is open, the door interlock disables the circult breaker.
NOTE :- INDIVIDUAL INSTALLATIONS MAY REQUIRE SPECIFIC TEST PROCEDURES NOT COVERED IN THIS SECTION. REFER TO DRAWINGS AND DATA FURNISHED WITH THE UNIT. REQUEST ADVICE FROM INDUCTOTHERNM ENGINEER IF THERE IS ANY DOUBT CONCERNING THIS INSTALLATION.
SCR OVP AND ACI RESET INTERLOCK SYSTEM (WHEREVER INSTALLED) CHECKS SHOULD BE PERFORMED BY INDUCTOTHERM SERVICE ENGINEER OR BY AN AUTHORIZED ENGINEER ONLY.
(3) AC INTERRUPTER CHECKS
Test procedure and precautions outlined in Section 4 4. Control Board Check(s), should be read and followed when checking out the ACI. The folowing checks should be made after ACI maintenance or on initial start-up The following check is made with the control power key lock ON but with the unit circuit breaker(s) OFF.
1 Before depressing “off-reser” button, check for 24VDC available between pins 3 and 4. and 5 and 4 on TB-103 of the ACI module Pins 3 and 5 should be postive with respect to pin 4 (common).
2 Check for-15VD.C between pins 2 and 4 and +15 VDC between pins 10 and 4 on TB 103 of the ACI module.
3 Depress the OFF-RESET button to start the ACI All the green LED’s on the ACI SCR firing module should begin to blink at a rale of about 2.5Hz. Venty that the blinking stops after about ane minutse.
4 Turn OFF the control power key switch for one minute.
5 Repeal steps 1 through 4 for additional ACIs as required.
6 Turn control power koy lock switch OFF for one minute.
7 Tum control power koy lock swilch ON.
8 Set circuit breaker to the ON position.
CAUTION :- HIGH VOLTAGE WILL BE PRESENT IN THE POWER SUPPLY WHILE THE FOLLOWING CHECKS ARE MADE. ALL DOORS SHOULD BE CLOS EXCEPT THOSE REQUIRED TO GIVE ACCESS TO THE ACI.
9 Depress the OFF-RESET button. The LEDs on the ACI SCR firing modules should at 2.5 Hz for a short time before coming on bnght This indicates that the AC transitioned from soft start to hard firing in response to the rising voltage on the DC bus-bar.
10 Place circuit breaker in the OFF position and switch control power key switch to off.
CAUTION :- ALLOW 5 MINUTES FOR FILTER CAPACITORS TO BLEED OFF BEFOR PROCEEDING WITH ADDITIONAL CHECKS. VERIFY BLEED-OFF WIn METER OR SHORTING STICK.
(4) CONTROL BOARD AND FREQUENCY SETTING CHECK
These checks should be performed by a trained and qualified factory service engineer.
WATER FOR COOLING IS NOT REQUIRED DURING THIS CONTROL CHECI TOWEVER, IP COOLING WATER IS NOT SUPPLIED, WPSI MUST BF JUMPERED TO MAINTAIN CONTROL CONTINUITY.
CAUTION :- BE SURE THAT THREE PHASE POWER FUSES ARE REMOVED PRIOFR PROCEEDING WITH THE FOLLOWING ADJUSTMENTS. FAILURE To OBSERVE THIS CAUTION COULD RESULT IN INVERTER COMPONE FAILURE .
This procedure should be followed whenever a new control board is installed or for initial start-up uf a new unit The following control board checks may be made without applying primary power to the unit.
The follawing procedure requires a multimeter (Simpson Rs-260 or similar) and an osciloscope Measure control board voltages as follows:
CAUTION :- MOST OSCILLOSCOPES USED A CHASSIS GROUND. THESE SCOPES CAN GET DAMAGED UNLESS THEY ARE ISOLATED FROM GROUND PRIOR TO DEIGN USED FOR MEASUREMENTS ON THE UNGROUNDED HIGH VOLTAGE CIRCUITS OF THE POWER-TRACK-R. THE SCOPE CHASSIS MUST BE ISOLATED FROM GROUND.
WARNING :- WHEN USED TO MEASURE VOLTAGES IN THE POWER-TRACK-R- SERIES SYSTEM, THE SCOPE CASE AND CHASSIS WILL BE AT AN ELEVATED VOLTAGE WITH RESPECT TO GROUND. EVEN THE SET SCREWS ON THE CONTROL KNOBS PRESENT A SHOCK HAZARD.
ALL SCOPE CONNECTIONS AND ADJUSTMENTS SHOULD BE MADE WITH MAIN SYSTEM POWER OFF. IF A MINOR SCOPE ADJUSTMENT MUST BE MADE WITH POWER ON THE UNIT, THE TECHNICIAN SHOULD STAND ON A RUBBER MAT OR A DRY BOARD TO ISOLATE HIMSELF FROM GROUND THE USE OF CERTIFIED INSULATING GLOVES IS ESSENTIAL. EACH TIME POWER IS INTERRUPTED TO CHANGE SCOPE CONNECTION OR ADJUSTMENTS, UP TO 5 MINUTES IS REQUIRED FOR THE CHARGE ON CAPACITORS TO DRAIN OFF COMPLETELY.
THE USE OF A SHORTING BAR WITH AN INSULATED HANDLE IS RECOMMENDED TO ENSURE THAT THE CHARGE HAS BEEN BLED OFF MULTIPLE FAILURES WITHIN THE EQUIPMENT WOULD HAVE TO OCCUR FOR THE HAZARD TO EXIST, HOWEVER THE USE OF A GROUNDING STICK ELIMINATES EVEN THIS REMOTE POSSIBILITY. USE OF A MULTI CHANNEL SCOPE IN THE DIFFERENTIAL MODE ELIMINATES THE LIVE CHASSIS HAZARD. MAKE TEST CONNECTIONS TO THE UNIT WITH TWO SEPARATE PROBES FROM WHICH THE GROUND LEADS HAVE BEEN REMOVED.
ON THE DUAL CHANNEL AMPLIFIER, PLACE THE DISPLAY MODE SELECT SWITCH TO “ADD” AND INVERT CHANNEL TWO. THIS IS THE ONLY SAFE METHOD OF MAKING SUCH MEASUREMENTS. REFER YOUR Oscilloscope MANUAL FOR DETAILS ON DIFFERENTIAL MODE OF OPERATION.
NOTE :- WHEN MAKING Measurements IN THE STEPS THAT FOLLOW, THE PROCEDURE BELOW SHOULD BE USED:
A. DE ENERGIZE THE UNIT.
B. CONNECT TEST EQUIPMENTS AS DESCRIBED.
C. RE-ENERGIZE THE UNIT AND PERFORM THE TEST.
D. DE ENERGIZE THE UNIT AND DISCONNECT THE TEST EQUIPMENT.
(4.1) TEST PROCEDURE FOR POWER-TRACK
1. Remove the main fuses.
2. Measure -24 VDC +- 1.2 volts from TB-103 pin 10 to TB-103 pin 9 (Pin 10 is t positive terminal, pin 9 is the negative ).
3. Measure -24 VDC +- 1.2 volts from TB-103 pin 11 to TB-103 pin 12 (Pin 11 is t positive terminal, pin 12 is the negative terminal).
4. If voltages are not as specified check for loose or broken wires Replace or repair required An addilional check may be made at the DC power supply (See VIP contro wiring diagram).
5. Reset the circuit monitor, GLD and ACI (If provided), then depress the inverter ON button. The control relay should energize The “reduced power lamp shauld be Depress the inverter OFF button
6. (a) Connect a scope to observe the output at terminals 1 and 2 of TB-102, with pin 2, t scope common.
(b) Press the inverter ON button Check for an ouiput as indicated in Figure 4-1 Th should be positve going to at least 16 volts ampítude with a pulse width of appro b) output starts approximately one second after the button is de-pressed.
c) With the “Power Control Knob” fully counterclockwise, for a pulse repetition time( between pulse) that corresponds to minimum frequency Appropriate times and waveforms are shown in Figures 4-1.
7. (a) Check terminals 3 and 4 on TB-102 for an output similar to that observed at pins 1 and 2. If a Dualtrak scope is used, the two signals can be displayed simultaneously, as illustrated in Figure 4-1. They will be 180° out of phase. That is the output from pins 3 and 4 will appear at the midpoint of the time interval between the pulses from pins 1 and 2 .
(b) Turn the control knob fully clockwise.
(c) Check for a pulse repetition time corresponding to the desired high frequency.
8. With the frequency at limit, frequency meter should show redline frequency Adjustment is proper when the frequency meter indicates frequency limit as per name plate.
9. Rotate the control knob through its full range rechecking idle frequency, limit frequency calibration and frequency limit light operation.
10. Reinstall the main fuses.
(4.2) TEST PROCEDURE FOR POWER-TRAK-R
1. Control power key switch ON.
NOTE :- SEE CONTROL WIRING DIAGRAM FOR TERMINAL DETAIL
2. Measure +24 VDC + – (1.2) volts from DC power supply, to the control board modules.
3. Measure -24 VDC + – (1.2) volts from DC power supply, to the control board modules.
4. If voltages are not as specified, check wiring for loose or broken wires. Repla modules modules repair as required. An additional check may be made at the DC power suppl VIP control wiring diagram)
5. Observe LEDs glowing on the control board & modules provided for healthy supply.
6. Reset the circuit monitor, GLD and ACI (if provided)
7 . (a) Connect a scope to observe the output at Terminals 1 and 2 of TB-102 with pin 2 5 6. 7a) scope common.
WARNING :- HIGH VOLTAGE WILL BE PRESENT IN THE CABINET FROM THIS PO ON. ALL DOORS EXCEPT THE CONTROL DOOR (THE DOOR WITH THI METERS ON IT) SHOULD BE CLOSED BEFORE PROCEEDING.
(b) Remove the fanning strip from Te 102 of the control board and support it s does not touch the terminal strip or the cabinet skin or frame.
(c) Close the unit circuit breaker Press OFF-RESET to reset the ACI
(d) Press the inverter ON buttan Check for an oulput as indicated in Figure 4-1 output starts approximately one second ater the button is depressed The should be positive going to atleast 16 volls amplitude with a pulse width of ap mately 15 microseconds. These are the firing pulses which cause SCR firing .
(e) With the “Power Control Knob” fully counterclockwise, for a pulse repetition timol be- tweon pulses) that corresponds to an idle frequency Appropriate times and waveforms aro shown in figures.
8. Check Terminals 3 and 4 on Te-102 for an output similar to that observed at pins 1 and 2 If a Dualtrak scope is used, the two signals can be displayed simultaneously, as llustrated in Figure 4 3 They will be 180 out of phase That is, the output from pins 3 and 4 will appear at the midpoint of the time interval between the pulses from pins 1 and 2.
(4.3) GROUND-LEAK DETECTOR START-UP
1. Ensure that the ground detector is installed and wired correcty.
2. Ensure that the ground wire connections (G) are properly connected to a solid cabinet ground. DO NOT connect this wire to a hinged door ground.
3. Turn ON control power Unit should come on in tripped mode The RED “current trip light will be ON.
The RED voltage trip light may or may not be ON.
The GREEN GLD ON” light will be OFF
4. Leakage current as read on the meter should be low if no high leakage paths are present about 3-5 ma is typical,
5. Observe that the polarity reversing circuit is operating. The leakage current will drop to zero momentarily as the polanty is reversed This occurs every 20 seconds
6. Depress the test button, Unit should trip
GREEN GLO ON light turns OFF
RED “current trip” light turn on.
Milliamps momentarily go to about 90 and then drop to zero. The Increase to 90 may not be noticeable on the meter ( with sensitivity pot on 0 % )
8. Depress reset button for one second. RED “current trip” light turns OFF GREEN “GLD ON” light turns ON.
9. Jumper the furnace bus to a suitable ground point. Unit should trip.
10. Depress and hold in reset button. Milliammeter should read approximately 90 mA. R lease reset button.
11. Remove ground on furnace bus. 12. Reset ground detector.
13. During normal operation keep sensitivity knob on 100 % . So as to trip at 60 mA . leak current.