Powercube Series 900 and 1800: Inductive Heaters

FI025GB40K5v1.
03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64
Inductive Heaters
PowerCube series 900 and 1800
Installation, Use and
Maintenance Manual
Document Revision Date Software version

FI 025 GB 40K5 v1.03 05/12/2008 MPWC71xx
Read this manual carefully before installing, operating or carrying out maintenance on the device. Keep the manual in a
safe place for future reference, and in perfect condition. This manual must accompany the device described therein in the
case of change of ownership, and until the device is broken up
1
FI025GB40K5v1.03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64
SYMBOLS
The equipment is marked with this symbol wherever the user should refer to this manual in order to avoid possible
damage. The same symbol appears in the manual at points where warnings or particularly important instructions,
essential for safe, correct operation of the device, are given.
The equipment is marked with this symbol in the areas where there is dangerous voltage. Only trained maintenance
personnel should carry out work in these areas. The same symbol appears in the manual at points where warnings
essential for safe, are given.
LASER LIGHT: This symbol appears in the present booklet at those points where warnings or information relating to
devices with laser pointing are given. Such devices may be dangerous. It is therefore essential that the guidelines
reported in this booklet be followed.
STRONG MAGNETIC FIELDS can affect pacermakers. Wearers of pacemakers, cardiac defibrillators and other
life supports, shall not operate in proximity of the inductor or the heating inductors of this device.
Wearers should consult their doctor before operating in a different way.
This symbol appears in the manual at points where suggestions, additional information or other relevant notes are given.
REVISION TABLE
Rev. Date Author Reference Description

1 23/07/2007 TP2 - SP - First emission
1.01 30/10/2007 TP2 – SP - Minor corrections
1.02 05/12/2008 TP2 – SP Par.2.8 Minor corrections
1.03 14/07/2009 TP2 - SP Par.6.1 EC Certificates updated
Warranty terms
The warranty on all CEIA products, extended to the period agreed with the Sales Department, is
applicable to goods supplied from our factory, and for every constituent part thereof, with the
exception of the batteries. Any form of tampering with the device, and in particular opening its
container, is strictly forbidden and will invalidate the warranty.
Customer Satisfaction Report
Your suggestions and comments on the products and services offered by CEIA and its
distribution network are extremely important for improving our procedures.
We would ask you to send them to us by compiling and returning the form available at:
http://www.ceia-power.com/satisfaction.asp
Thank you for your kind interest and co-operation.
2
CONTENTS
SYMBOLS ...............................................................................................................................................................2
REVISION TABLE...................................................................................................................................................2
WARRANTY TERMS................................................................................................................................................2
CONTENTS .............................................................................................................................................................3
1 - SAFETY INSTRUCTIONS - WARNINGS..........................................................................................................5
1.1 - WARNINGS ...................................................................................................................................................5
1.1.1 – General warnigns............................................................................................................................................... 5
1.1.2 – Installation warnings .......................................................................................................................................... 5
1.1.3 – Use warnings ..................................................................................................................................................... 6
1.1.4 – Maintenance warnings ....................................................................................................................................... 7
1.2 – RESIDUAL RISKS ...........................................................................................................................................7
1.2.1 – Use .................................................................................................................................................................... 7
1.2.2 – Maintenance ...................................................................................................................................................... 7
1.3 – CORRECT AND FORBIDDEN USE OF THE DEVICE .............................................................................................8
1.3.1 – Correct use of the device ................................................................................................................................... 8
1.3.2 –Forbidden use of the device................................................................................................................................ 8
2 - DESCRIPTION ...................................................................................................................................................9
2.1 – GENERAL DESCRIPTION ................................................................................................................................9
2.1.1 – Description ......................................................................................................................................................... 9
2.2 – FUNCTIONAL DIAGRAM .................................................................................................................................9
2.3 - COMPONENTS .............................................................................................................................................10
2.3.1 – PowerCube 32/45 ............................................................................................................................................ 10
2.3.2 - PowerCube 64 .................................................................................................................................................. 10
2.3.3 – Heating Head ................................................................................................................................................... 11
2.3.4 - Available adductors .......................................................................................................................................... 12
2.3.5 - Adjustable supports for heating heads.............................................................................................................. 12
2.3.6 - Activation pedal ................................................................................................................................................ 14
2.4 - SAFETY DEVICES AND WARNING LABELS .......................................................................................................14
2.5 – OPTIONS....................................................................................................................................................14
2.6 - ACCESSORIES.............................................................................................................................................15
2.6.1 – Heating head HH10 ......................................................................................................................................... 16
2.6.2 – Heating head HH11 ......................................................................................................................................... 16
2.6.3 – Heating head HH15 ......................................................................................................................................... 16
2.7 – SPARE PARTS ............................................................................................................................................17
2.7.1 – PowerCube 32/900 .......................................................................................................................................... 17
2.7.2 – PowerCube 45/900 .......................................................................................................................................... 17
2.7.3 – PowerCube 64/900 .......................................................................................................................................... 17
2.7.4 – PowerCube 32/1800 ........................................................................................................................................ 17
2.8 – TECHNICAL CHARACTERISTICS ....................................................................................................................18
2.8.1 – Common features ............................................................................................................................................ 18
2.7.2 – Different features ............................................................................................................................................. 18
2.8.3 – Heating heads.................................................................................................................................................. 19
3
3 - INSTALLATION ...............................................................................................................................................20
3.1 – MECHANICAL INSTALLATION ........................................................................................................................20
3.1.1 – Minimum requirements .................................................................................................................................... 20
3.1.2 – Assembly ......................................................................................................................................................... 20
3.1.3 – Transportation ................................................................................................................................................. 20
3.1.4 – Heating head fastening.................................................................................................................................... 20
3.2.5 – Cooling system ................................................................................................................................................ 21
3.3 - ELECTRICAL INSTALLATION ..........................................................................................................................23
3.3.1 – Minimum requirements .................................................................................................................................... 23
3.3.2 – Selection and installation of the connecting cables ......................................................................................... 23
3.3.3 – Connection of the heating heads ..................................................................................................................... 23
3.3.4 – Connection of the activation pedals ................................................................................................................. 24
3.3.5 – Connections for the analogic adjustment of the output power (optional) ......................................................... 24
3.3.6 – Connection to the power supply ...................................................................................................................... 25
3.3.7 – Serial connection (PowerCube 64) .................................................................................................................. 25
3.3.8 – Connection to other devices of the PowerCube Family ................................................................................... 26
3.3.9 – Connection to an external signalling relais ...................................................................................................... 26
4 - USE OF THE DEVICE......................................................................................................................................27
4.1 - INDICATORS ................................................................................................................................................27
4.1.1 – Optical indicators ............................................................................................................................................. 27
4.1.2 – Display messages ........................................................................................................................................... 27
4.1.3 – Acoustical indicators ........................................................................................................................................ 28
4.2 – CONTROLS .................................................................................................................................................28
4.3 – USE OF THE DEVICE ....................................................................................................................................28
4.3 - PROGRAMMING ...........................................................................................................................................29
4.3.1 - Selection of the head and regulation of the heating power............................................................................... 29
5 - MAINTENANCE ...............................................................................................................................................30
5.1 – PERIODICAL MAINTENANCE .........................................................................................................................30
5.2 - REPLACEMENT OF THE SUPPORT-HEATING INDUCTOR GROUP ........................................................................30
5.2.1 – Heating inductor soldering ............................................................................................................................... 30
5.2.2 - Support-heating inductor group replacement procedure .................................................................................. 31
5.3 - TROUBLESHOOTING.....................................................................................................................................31
6 - APPENDICES ..................................................................................................................................................33
6.1 – DECLARATIONS OF CONFORMITY CE...........................................................................................................33
6.1.1 – PowerCube 32/900 .......................................................................................................................................... 33
6.1.2 – PowerCube 32/1800 ........................................................................................................................................ 34
6.1.3 – PowerCube 45/900 .......................................................................................................................................... 35
6.1.4 – PowerCube 64/900 .......................................................................................................................................... 36
6.2 - SHAPE AND POSITION OF THE INDUCTOR .......................................................................................................37
6.2.1 - Flow of Cooling Water ...................................................................................................................................... 37
6.2.2 - Dimensions of the heating inductor .................................................................................................................. 38
6.2.3 - Dimensions of the heating inductor .................................................................................................................. 39
6.2.4 - Optimisation of the generator efficiency with small dimension inductors .......................................................... 39
6.3 - CONSTRUCTION OF EQUIPMENT, CLAMPS, AND MATRIXES ..............................................................................40
6.3.1 - Materials to use ................................................................................................................................................ 40
6.3.2 - Dimensions of the parts.................................................................................................................................... 40
6.4 - USE OF ANTI-OXIDIZING GAS ........................................................................................................................41
6.5 – CONTROL VIA RS232 SERIAL INTERFACE .....................................................................................................41
6.5.1. Setting of the Terminal....................................................................................................................................... 41
6.5.2. Starting of the connection .................................................................................................................................. 41
6.5.3. Commands ........................................................................................................................................................ 42
4
SAFETY INSTRUCTIONS - WARNINGS 1
Read this manual carefully before installing, operating or carrying out maintenance on the device.
1 - SAFETY INSTRUCTIONS - WARNINGS
1.1 - Warnings
1.1.1 – General warnigns
- Soldering processes which have been developed over the years may be employed with a
high degree of safety provided that all the safety regulations suggested by common sense
and by the manufacturer's recommendations are observed. It is therefore essential that
heads of staff safety make sure that all operators read this manual before being allowed to
use the device.
- Follow the instructions contained in this manual for all operations relating to installation, use
and maintenance of the device. CEIA cannot be held responsible for any damage resulting
from procedures which are not expressly indicated in this manual, or from any lack of
attention, either partial or total, of the procedures described therein.
- Whenever there is any suggestion that the level of protection has been reduced, the device
should be taken out of service and secured against any possibility of unintentional use, and
authorised service technicians should be called.
The level of protection is considered to have been reduced when:
- the device shows visible signs of wear and tear, especially on parts that ensures the
device protections (boxes, gaskets, glands, fixing screws, etc.);
- the electrical cables or the equipotential ground connections are damaged.
- the ground connections are not compliant;
- the device has suffered mechanical or electrical stress (shocks, bumps, etc..);
- the device does not operate correctly, respect on how described in this manual;
- the device has been stored for long periods in sub-optimal conditions;
- the device has suffered severe stress during transport;
- the inside of the device has come into contact with liquids.
- the device was present inside an environment where a fire or an explosion took place.
- This equipment complies with European (CE) and International Standards on Electrical
Safety and Electromagnetic Compatibility. However, CEIA will not accept any liability for
damage to objects or people due to improper use or to specific incompatibility with
equipment of a different nature.
1.1.2 – Installation warnings

The device is designed to be inserted as a component part of a heating system; the safety devices needed to protect the
operators must therefore be designed and fitted by the installer according to the type of application in question.
- Ensure that there is adequate fire-fighting equipment sufficiently close to the working area.
- Choose the installation site carefully. Avoid placing the device in locations where it may be
directly exposed to sunlight or in places that are close to sources of heat. In addition, avoid
places that are subject to vibrations, dust, humidity, rain and excessively high or low
temperatures.
- Handle the device with care and without excessive force during installation, use and
maintenance.
- The operator must be able to access the controls of the device easily, without running
personal risks.
- To avoid damage due to lightning, fit the power supply line with appropriate surge
suppressors.
- This device contains electrical and electronic components, and may therefore be susceptible
to fire. Do not install in explosive atmosphere or in contact with inflammable material,
5
1
FI 023 I 2K8 v2 – Manuale Istruzioni THS/G-ATEX
SAFETY INSTRUCTIONS - WARNINGS
- After installation the device should be stable, and not subject to vibration or accidental
movement. All connecting cables should be properly fastened down, in order to avoid knocks
and accidental damage and to obtain optimum performance.
- If the device is to be powered via an external autotransformer to regulate the voltage, ensure
that the common terminal of the autotransformer is connected to the neutral of the power-
supply circuit.
- The electrical plug must only be inserted into a socket containing a grounding contact. Any
interruption in the protective conductor either inside or outside the device, or the detaching of
the protective grounding terminal, renders the device dangerous. Intentional interruption is
forbidden.
- Before providing the device with electrical power, check that the voltage from the power
mains corresponds to the voltage shown on the device's electrical specifications plaque.
- Only connect the device to the power mains after having made all the connections needed
for its complete installation.
1.1.3 – Use warnings

- Never carry out soldering operations on metal pieces that have been in contact with toxic
combustible products; such pieces must be carefully cleaned before undergoing any
soldering operations.
- Maximum care must be taken to avoid incandescent metals coming into contact with
combustible materials.
- Ensure that there is adequate fire-fighting equipment sufficiently close to the working area.
- All combustible materials must be removed from the working area and placed at a safe
distance.
- During the generating phase do not allow limbs or other parts of the body bearing metal to
come near the heating coil. The minimum safety distances of 50cm must be maintained
during generator activation.
- During normal use, the heater does not produce sparks. Electrical discharges may however
occur during soldering, near the heating inductor, in the event of accidental contact between
the inductor and metal parts with a ground connection.
- ATTENTION! This device may be equipped with an optical pyrometer with laser pointing.
Use of the device for operations or functions not expressly indicated in this booklet may
cause exposure to dangerous radiation.
LASER LIGHT
DO NOT STARE INTO BEAM OR VIEW
DIRECTLY WITH OPTICAL INSTRUMENTS
CLASS 3A LASER PRODUCT (EN 60825-1:1994)
- After soldering, ensure that the piece that has been worked upon is allowed sufficient time to
cool before handling it or bringing it into contact with combustible material.
- All electrical shocks are potentially fatal. Never touch parts charged with mains power. Keep
clothes and body dry and never work in wet environments. If you ever have cause to believe
that the device or part of it has accidentally become electrically charged, stop soldering
operations immediately and do not use the device until the problem has been located and
resolved by qualified personnel.
- Always remove the plug by hand when disconnecting the power supply cable, never by
pulling on the cable.
- This device contains electrical and electronic components. Do not use water or foam in the
case of fire when the device is powered up.
6
SAFETY INSTRUCTIONS - WARNINGS 1
1.1.4 – Maintenance warnings
- Do not wash the device with liquid detergents or chemical substances. Any cleaning should
be done using a slightly-damp, non-abrasive cloth.
- Before any maintenance, cleaning or movement, the device must first be disconnected from
all sources of power.
- Read the chapter on "Maintenance" carefully before calling the service centre. Whatever the
problem, only specialised service personnel authorised to work with CEIA equipment should
be called.
- Any damaged parts of the device should be replaced with original components only.
- Any maintenance or repair of the device while open and energised should be avoided, and in
any case should only be carried out by trained personnel who are fully aware of the risks
which the operation entails, following the instructions given in the Maintenance section.
1.2 – Residual risks

1.2.1 – Use
- In particular, direct or indirect contact with

the heating inductor must be prevented,
and the following minimum safety
distances must be maintained during
generator activation: 5 cm for metal
objects and parts of the body. At
distances less than the above safety
limits, heating of metal objects may occur
even without direct contact, with a
consequent risk of burns for the operator.
- During activation of the generator the heating inductor is powered at a dangerous voltage (as
per regulation CEI EN 61010-1, par. 6.3.1): avoid direct contact and indirect contact via
metal objects.
1.2.2 – Maintenance
- The capacitors within the device may remain charged even after the device has been
disconnected from all sources of power. Wait 60 seconds before beginning repair work on
the device.
7
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FI 023 I 2K8 v2 – Manuale Istruzioni THS/G-ATEX
SAFETY INSTRUCTIONS - WARNINGS
1.3 – Correct and Forbidden use of the device

1.3.1 – Correct use of the device
The device is designed to be inserted as a component part of a heating system; the safety devices needed to protect the
operators must therefore be designed and fitted by the installer according to the type of application in question.
- The PowerCube 32/45/64 generators are induction heaters dedicated to the soldering,
without contact, of metal components. Any other use shall be avoided.
1.3.2 –Forbidden use of the device

- During the generating phase do not allow limbs or other parts of the body bearing metal to
come near the heating coil. The minimum safety distances of 50cm must be maintained.
- The heating phase shall not be started, for any reason, in presence or in the nearby of tanks
under pression, explosive or inflammable atmosphere or liquids.
- Any different use, from the specifications of paragraph 1.3.1 - Correct use of the device, is
forbidden.
8
DESCRIPTION 2
2 - DESCRIPTION
2.1 – General description
2.1.1 – Description
The basic configuration of the Inductive Heater PowerCube is as follows:
- a programmable generator, controlled by microcomputer;
- two miniaturized heating heads with adjustable supports;
- two on/off pedals to activate the working cycle.
The device is also designed to be connected to other devices from PowerCube Family.
The system can be fitted with a pyrometer in order to control the temperature of the piece being
worked upon (option) and an Anti-oxidizing gas diffusion system placed near the heating area.
2.2 – Functional Diagram

An inductor with a suitable shape (IND) connected to the head emits an electromagnetic field.
Metals located within the inductor heat up due to the currents induced by this magnetic field:
The shape of the inductor depends on the type of application; CEIA does not physically supply the head, which must be
produced by the heating system constructor.
Block diagram of a PowerCube 32 soldering station.

M: metal object to be heated; IND: heating inductor
9
2
DESCRIPTION
2.3 - Components
2.3.1 – PowerCube 32/45
The generator of the models PowerCube 32 and PowerCube 45 is made up of a central
electronics unit which includes a power supply stage, a generator of high frequency and a control
section .
The management of the apparatus is entrusted to a microcomputer that monitors the correct
functioning of the machine by means of a self-diagnosis device and signals, by display, any
necessary interventions on the part of the operator.
1 Alphanumeric display which shows the functioning messages
2 Two push-button for the regulation of the power delivered by the

heads
3 Indications about the self-diagnosis messages (see Maintenance
chapter) and the functioning of the equipment
4 Magnetothermal on/off switch
5 Power supply cable
6 The connectors and terminals necessary for the installation of the

device
7 Label with the indications of the power supply, the model of the
equipment and the serial number
2.3.2 - PowerCube 64
The generator of the PowerCube 64 is made up of two
central electronics units:
- a unit for the management and the programming
MAIN UNIT
- a supporting unit SLAVE UNIT.
the two central electronics units include a power supply

stage, a generator of high frequency and a control section.
The management of the apparatus is entrusted to a
microcomputer that monitors the correct functioning of the
machine by means of a self-diagnosis device and signals, by
display, any necessary interventions on the part of the
operator.
10
DESCRIPTION 2
2.3.3 – Heating Head
The PowerCube generator allows connection to different heating heads, one for each soldering
point:
- HH10 model for PowerCube 32/900 and 45/900;
- HH10 model for PowerCube 32/1800 (only on Spectacle Frame Line)
- HH11 model for PowerCube 64/900.
- HH15 miniaturised model (only for PowerCube 32/900, 32/1800 and 45/900).
The container of the head  is constructed of plastic with a high thermal and mechanical
resistance. From the front a metal connection (conductors ), comes out upon which the inductor
 that generates the electromagnetic field is soldered. Above the connection there is a luminous
indicator , which signals the operation of the head. On the back there is the exit of the
connecting cable to the generator  and two connections for the head cooling water .
Heating head HH10 (* refers to model 32/1800)
Heating head HH15
11
2
DESCRIPTION
2.3.4 - Available adductors

In addition to the standard adductor, suitable for general use, a shortened adductor with larger-
diameter tubes (3mm instead of 2mm) is also available. This special adductor is designed for
continuous use at high power: the greater flow of water prevents overheating of the inductor.
29 29
ø2 ø2
29 ø3
50 50
82.5 82.5 50
150 100 65
Standard adductor (tube ø2mm) Standard adductor for model 32/1800 Short adductor, specifically for
(tube ø2mm) inductors with a high cooling flow-rate
(tube ø3mm)
2.3.5 - Adjustable supports for heating heads

The head can be furnished with an adjustable support for the positioning of the inductor in the
work area.
Standard adjustable support ES25

The support allows a micrometric movement of the head along the horizontal axes, a weighted
movement vertically (the movement measurements are shown in the illustration), and a rotation of
360°.
62,5 150 123

95
42 ± 142
~80
60
M5
60
20mm 20mm
20mm 20mm
Adjustable support ES25
12
DESCRIPTION 2
Adjustable precision support for heating head ES35L/R

Two different positioning supports are available: ES35L (left point) and ES35R (right point); the
supports are constructed specularly to allow easy positioning on symmetrical workstations.
The support allow a micrometric movement of the head along the horizontal axes, a weighted
movement vertically (the movement measurements are shown in the illustration), and a rotation of
360°
ø5,5
60
80
24
1
M5
360˚
13,5
±11
3
159
±11 ±11
2
1
1 78
100 80
146 136
adjustable precision support ES35L
13
2
DESCRIPTION
2.3.6 - Activation pedal

The PowerCube can be connected to two pedals for
the activation of each of the soldering heads.
In the case of remote command, the pedal can be
substituted by a button which is normally open.
2.4 - Safety devices and warning labels
IP Protection degree The device has a protection degree IP20

Selfdiagnosis system Built-in. See paragraph 5.3 of this manual
2.5 – Options
Options Part Number

Standard PW3-32/900-IND
PowerCube 32/900
Industrial Line With analogic adjustment
PW3-32/900-IND-AC
of the power output
Standard PW3-32/900-FRM
PowerCube 32/900
Spectacle Frames Line With analogic adjustment
PW3-32/900-FRM-AC
of the power output
PowerCube 32/1800
PW3-32/1800-FRM-AC
of the power output
PowerCube 45/900
PW3-45/900-IND-AC
of the power output
PowerCube 45/900
PW3-45/900-FRM-AC
of the power output
PowerCube 64/900
PW3-64/900-IND-AC
of the power output
PowerCube 64/900
PW3-64/900-FRM-AC
of the power output
14
DESCRIPTION 2
2.6 - Accessories
Accessory Part Number
Activation pedal 3457
1000x700x1370 working desk

25908
with raised shelf for generators and controllers
Standard adductors kit - 150mm

- 32836
(1 adductor, 6 o-ring, 4 screws and a tool)
1800 series adductors kit - 100mm
- 32837
Short adductors kit - 70mm
- 32838
- Assembled standard adductor - 150mm 3459
- Assembled 1800 series adductor - 100mm 14123
- Assembled short adductor - 70mm 3461
ES25 heating head support 3454
ES35 precision heating head support 9252

ES35/P precision heating head support
30313
with pneumatic movements
ES35/PS precision heating head support
31166
with pneumatic movements and positioning sensors
Ceramic cylinder - ø5 L100mm 29101
-
Ceramic cylinder - ø3 L100mm 16633
- ø5 spare o-rings kit (25 pieces) 32839
- Adductors spare screws kit (8 pieces) 32841
- Coil kit (1m of tube, 1m of tin) 32842
3mm coil kit (2m of tube, and sheath)
- 32843
Only for HH10 and HH11
Copper tube
- 35514
Only for HH10 and HH11
- Sheath in insulating vetrotex 20096
15
2
DESCRIPTION
2.6.1 – Heating head HH10
Accessory Spare part
Full HH10 heating head
1.5 m cable length PWH-10-XX-15/900
Custom cable length PWH-10-XX-CC/900
16
DESCRIPTION 2
2.7 – Spare parts
Spare part Part number

- ALM Power supply card 43588
2.7.1 – PowerCube 32/900

- SCD Control card 43589
- PTS Card 43586
- PTZ Mosfet card 43590
2.7.2 – PowerCube 45/900

- PTS Card 43587
2.7.3 – PowerCube 64/900

- SCD Control card – Main unit 43591
- SCD Control card – Slave unit 43592
- PTS Card 43593
2.7.4 – PowerCube 32/1800

- PTS Card 43598
17
2
DESCRIPTION
2.8 – Technical characteristics

2.8.1 – Common features
Power and supplies Power supply 180-260V~, monophase - 50/60 Hz
Cooling Water cooling system Water cooling, by means of tank of 200dm3 with 0.4 Hp pump or with direct
pressure of about 300kPa (minimum pressure of 150kPa, maximum pressure
of 600kPa):
Input water temperature From environmental temperature to a maximum of 45°C (without condense)
Operational mode Spectacle Frame Line Intermittent activation of one head
Intermittent activation and alternated over two heads
Industrial Line Continued activation of one head
Alternated activation over two heads
Command mode Manual or Automatic (controlled by a device of the PowerCube Family)
Management Cycle activation by means of pedal or external control
and controls Analogic regulation of the heating power through 0 ÷ 10 V input (optional)
Heating power automatically stabilised (not influenced by variations in the power supply)
Digital regulation of the heating power: 10 - 99 %
Self-diagnosis Any malfunctioning is Monitors of the temperature and
Monitors of that the coil size is correct
indicated by a display pressure of the cooling water
signal and a buzzer Monitors of possible short-circuit of
Monitors of head connection
the heating coil
Monitors of the power supply voltage
Internal malfunctioning
value
Monitors of the correct connection between the Main Unit and the Slave Unit
(PowerCube 64)
Generator Type Container in stainless steel
Dimensions (W x D x H) 275 x 265 x 140 mm / 10.8x10.4x5.5 in
(the PowerCube 64 comprises two control units of the same dimensions)
Power supply cable 2,6 m
Hydraulic connection to 1/8" connections by 6/4 mm rubber tube (PowerCube 32 and 45)
and from the cooling unit 1/8" connections by 8/6 mm rubber tube (PowerCube 64)
Hydraulic connection to
1/8" connections by 6/4 mm rubber tube
and from the heating heads
Safety features Power supply feed galvanically insulated
Low operational voltage: no danger to the operator
Conform to the international standards currently applicable for electrical safety, E.M.C. and to the applicable
CE regulations
Operating Working temperature +15 / +55 °C
conditions Storage temperature -20 / +70 °C
Relative humidity 0 – 95% (without condense)
2.7.2 – Different features

PowerCube 32/900 PowerCube 45/900 PowerCube 64/900
& 32/1800
Generator Input current 13A max 16A max 2 lines for 13A max
Ext. conduct. ø2.5 min. Ext. conduct ø4 min. Ext. conduct ø2.5 min.
Average power at inductor 32 kVAR 45 kVAR 64 kVAR
Weight 10 kg 10 kg 20 kg
Cooling Water flow for each
from 1.5 to 2 l/min from 1.5 to 2 l/min from 4 to 5 l/min
connected head
18
DESCRIPTION 2
2.8.3 – Heating heads
Common Weight 2 kg
characteristics Cable for the connection
Length 1.5 m – 10 pins connector
with generator
Inductors shape
In their construction the use of a silver-plated copper tube is advised (external
corresponding to the piece
diameter of 1.8 mm)
being worked upon
Hydraulic connection to and
1/8" connections by 6/4 mm rubber tube, length 1.5m
for electronics unit
PWH-10-XX-XX/900 Model PowerCube 32 & 45
Dimensions (WxDxH)
62.5x123x95 mm / 2.5x4.8x3.7 in
without adductor
PWH-11-XX-XX/900 Model PowerCube 64
Dimensions (WxDxH)
62.5x123x95 mm / 2.5x4.8x3.7 in
without adductor
PWH-15-XX-XX/900 Model PowerCube 32 & 45
Dimensions (WxDxH)
52x107x77 mm / 2x4.2x 3 in
without adductor
19
3
INSTALLATION
3 - INSTALLATION
Before starting any installation operation, read carefully the Safety instructions - Warnings section of this manual.
3.1 – Mechanical installation

3.1.1 – Minimum requirements
Position and fasten the soldering workstation components according to the processing required in
order to allow installation, bearing in mind:
- the length of the connecting cables;
- the electrical and hydraulic requirements;
- the modes of fastening.
Arrange the two workstations, installing the parts in such a way as to facilitate processing.
3.1.2 – Assembly
The PowerCube 32/45/64 is supplied already assembled.
3.1.3 – Transportation
Hold tightly the generator through its handlings.
3.1.4 – Heating head fastening

The heating head must be fastened to the working desk or to an adequate positioning support. See
the drawings below for the fixing holes and distances.
HH10 Heating head
HH15 Heating head
20
INSTALLATION 3
3.2.5 – Cooling system

For the cooling system characteristics see paragraph Technical characteristics.
PowerCube 32 and 45
- Connect the output of the external cooling unit to the "H20 IN" terminal of the central
electronics unit; insert a security tap up-flow.
ATTENTION! The cooling water, entering the generator, shall go from environmental temperature up to a maximum of
45°C, without condensation.
- Connect the input of the external cooling unit to the "H20 OUT" terminal of the central
electronics unit.
WARNING! Do not invert load and drain: in this case, the generator will not start.
- Connect the water connections of

Head 1 to the "H2O IN 1" and
"H2O OUT 1" terminals of the
central electronics unit.
central electronics unit.
COOLING
SYSTEM
In case of installation of the generator

with only one head, it is necessary to
insert the special cap (PS24) in the
"H2O OUT 2" and "H2O IN 2"
terminals.
COOLING
SYSTEM
IMPORTANT! - Flow of Cooling Water

For correct operation the flow must not be less than the minimum for each model as stated in the “Technical
Characteristics” section of the manual. The use of inductors constructed with tubes of reduced diameter or of a shape
which creates constriction (severely reduced dimensions or sharp bends) may cause a decrease in the flow sufficient to
result in inductor overheating. If process requirements necessitate the use of this type of inductor, the water input
pressure must be increased, remaining within the limits stated in the “Technical Characteristics” section.
21
3
INSTALLATION
PowerCube 64
- Connect the output of the external cooling unit to the "H2O IN" terminal of the SLAVE UNIT;
insert a security tap up-flow.
- Connect the "H2O OUT" terminal of the SLAVE UNIT to the "H2O IN" terminal of the MAIN
UNIT
- Connect the input of the external cooling unit to the " H2O OUT" terminal of the MAIN UNIT.
WARNING! Do not invert load and drain: in this case, the generator will not start.

MAIN UNIT.
MAIN UNIT.
COOLING
SYSTEM
In case of installation of the generator

with only one head, it is necessary to
insert the special cap (PS24) in the
"H2O OUT 2" and "H2O IN 2"
terminals of the MAIN UNIT
COOLING
SYSTEM
IMPORTANT! - Flow of Cooling Water

For correct operation the flow must not be less than the minimum for each model as stated in the “Technical
Characteristics” section of the manual. The use of inductors constructed with tubes of reduced diameter or of a shape
which creates constriction (severely reduced dimensions or sharp bends) may cause a decrease in the flow sufficient to
result in inductor overheating. If process requirements necessitate the use of this type of inductor, the water input
pressure must be increased, remaining within the limits stated in the “Technical Characteristics” section.
22
INSTALLATION 3
3.3 - Electrical installation
3.3.1 – Minimum requirements
See the values indicated on paragraph 2.7 – Technical characteristics.
3.3.2 – Selection and installation of the connecting cables

All cables needed to use PowerCube 32, 45 and 64 are supplied. Do not use different cables.
3.3.3 – Connection of the heating heads

PowerCube 32 and 45
Connect the cable of the Head 1 into
the socket "HEAD 1" and the cable of
the Head 2 into the socket "HEAD 2" of
the central unit; tighten well the metal
ring of the connector.
PowerCube 64
Connect the cables of the Head 1 into
the sockets "HEAD 1" and the cables of
the Head 2 into the sockets "HEAD 2"
of the two control units; the two cables
of each head are interchangeables.
Tighten well the metal ring of the
connectors.
23
3
INSTALLATION
3.3.4 – Connection of the activation pedals
PowerCube 32 and 45
Connect the PE10 activation pedals to
pins 6 and 7 of the connector
"ACTIVATION HEADS", to activate the
station 1 and to pins 8 and 9 to activate
the station 2.
PowerCube 64
Connect the activation pedals as
indicated above, on the MAIN UNIT.
Delay in Power activation: the delay, in

Pedal switch
power activation, after pressing the pedal,
is:
- step up (t1): 2 … 3 ms Output power
- step down (t2): 2 … 3 ms t1 t2
3.3.5 – Connections for the analogic adjustment of the output power (optional)
PowerCube 32 and 45
The connection with the external control
unit, for the analogic adjustment of the
output power, is performed through the
pins 3 and 4 of connector “ACTIVATION
HEADS”, for the station 1, and the pins 3
and 5 for the station 2.
PowerCube 64
Connect the analogic adjustment as indicated above, on the MAIN UNIT.
Power adjustment P
Power / voltage ratio: The power output 99%

isproportional to the input control voltage,
in the range 10%…99%. When the control
input is lower than 1V, the generator is
deactivated. 50%
10%
0 1 5 10 V
Delay in Power adjustment: The control
Control 10V
voltage is sampled approximatively each
Voltage 0V
millisecond. The delay, in power
adjustment, after a variation of the control 90%
voltage, is: Output Power
10%
- step up (t1): 1 … 2 ms t1 t2
- step down (t2): 2 … 3 ms
24
INSTALLATION 3
Enabling the remote control of the output power

The option with the remote control of the output power can be enabled independently for each one
of the heating heads.
The option is activated setting the power parameter on value "RE". This value can be set by
pressing the down arrow when the lower limit is reached (10%) or the up arrow when the upper
limit is reached (99%).
3.3.6 – Connection to the power supply

Connect the apparatus to the mains only after all the connections needed for the complete installation have been
carried out.
Using the power supply cable, connect the
machine to the earth and to the frequency
specified on the electrical-specifications plaque.
PowerCube 32 and 45 PowerCube 64
The external line shall have conductors with an section adequate to the absorbed current (see “Technical
Characteristics”).
3.3.7 – Serial connection (PowerCube 64)

Connect the serial cable to the SUB-D 25 poles
female connectors (signed with the symbol
shown beside) of the two electronics units.
The cables is marked, near the connectors, the control unit

to which that side shall be connected (MAIN or SLAVE
UNIT): respect this indication.
25
3
INSTALLATION
3.3.8 – Connection to other devices of the PowerCube Family

PowerCube 32 and 45
For connection to other devices of the
PowerCube Family, as Power Controller or
Master Controller, use connector "AUXILIARY
OUTPUT", type sub-D 9-pole female.
PowerCube 64
For connection to other devices of the
PowerCube Family, as Power Controller or
Master Controller, use connector "AUXILIARY
OUTPUT", type sub-D 9-pole female, of the
MAIN UNIT.
With the exception of contact 9, which has a voltage of 24Vcc, the connections are analogous to a normal RS232
interface.
3.3.9 – Connection to an external signalling relais

PowerCube 32 and 45
The connection with an external signalling
relais is performed through pins 1 and 2
of the connector “ACTIVATION HEADS”.
OUTPUT 24VDC / 24VAC - 0,5 AMAX
PowerCube 64
Connect the external relais as indicated
above, on the MAIN UNIT.
This output can be set to signal the presence of an alarm (default) or to signal when the generator
is ON. See parameter _RO in Serial Programming, at paragraph 6.5.3.
26
USE OF THE DEVICE 4
4 - USE OF THE DEVICE

Follow the instructions contained in this manual for all operations relating to the use of the device. CEIA cannot be held
responsible for any damage resulting from procedures which are not expressly indicated in this manual, or from any
failure, either partial or total, to put the procedures described into practice.
4.1 - Indicators
4.1.1 – Optical indicators
a Control unit display
b Heating head LED
4.1.2 – Display messages

Machine in stand-by
When working normally, with the generator in stand-by, the

PowerCube display shows which head of the two has been
selected and which was the power programmed for the head
H1 99 H1
Head 1 selected,
delivered power = 99%.
Soldering activation
During soldering, the display shows the power supplied by

the inductor, step by step; when the pedal is pressed, power
increases very fast up to reaching the programmed power.
46 88 99
Preset power = 99%.
Self-diagnosis messages
In case of failure, the display shows a message referred to

the problem; for decoding this message and solving the
problem, please see chapter "Maintenance" of the present
A1
booklet. Self-diagnosis message A1:
water temperature too high
Slave Unit PowerCube 64
Machine in normal functioning. When working normally, with

the generator in stand-by, or during a soldering cycle, the
Slave Unit display shows an "on" signal
on
SLAVE UNIT: normal functioning
27
4
USE OF THE DEVICE
4.1.3 – Acoustical indicators

The Self-Diagnosis system of each PowerCube warns the operator, in case of fault, through a
series of self-diagnosis messagges visualized by the controller display and through an acoustical
sound.
4.2 – Controls
The PowerCube induction heaters are designed to function in different ways depending on
whether or not they are connected to external control devices:
1. Apparatus not connected to any external control: the selected head is activated and
continues the heating of the piece being processed for the entire time that the activation
pedal is pressed. In this case, the operator controls all the soldering phases.
2. Apparatus controlled by one of the controllers of the PowerCube Family : the

PowerCube can be the generating part of a soldering workstation controlled by a device of
the "PowerCube Family". The device can be a Power Controller or a Master Controller.
These apparatuses control all the required devices in a soldering cycle, such as for example
diffusers of anti-oxidizing gas, temperature sensors and soldered-wire feeders (only with
Master Controller). The PowerCube itself is also completely controlled by these devices.
For information about the apparatuses of PowerCube Family contact our sales department
or the nearest distributor.
4.3 – Use of the device

The list of operations that follows assumes that the inductor, any equipment for positioning the
piece to be processed and any accessory devices have already been manufactured and properly
positioned during the welding system installation phase, so that the operator can carry out the work
cycle correctly and safely.
Before operating the equipment, all safety measures designed to prevent parts of the body or objects approaching the
heating inductor during activation of the generator must be put in place.
1. Turn on the necessary power and water supplies, then activate the on/off switch located on
the rear panel of the generator.
2. Position the heating head so as to facilitate the desired process (see next pages).
At the beginning of every working shift, check the efficiency and physical integrity of the safety devices designed to
prevent the operator approaching the inductor during heating.
3. Adjust the power delivered by heads 1 and 2

4. Position the pieces to be soldered close to the heating coil, making sure that they do not
touch the coil (see next pages).
28
USE OF THE DEVICE 4
In particular, direct or indirect contact with the heating inductor must be prevented and the minimum safety distance of
5cm must be maintained during generator activation.
At distances less than the above safety limits, heating of metal objects may occur even without direct contact, with a
consequent risk of burns for the operator.
During activation of the generator the heating inductor is powered at a dangerous voltage (as per regulation CEI EN
61010-1, par. 6.3.1): avoid direct contact and indirect contact via metal objects.
5. Soldering cycle:
manual mode: press the activating pedal, bring the piece to the desired temperature, solder,
and deactivate the heating.
automatic mode (heater connected up to external control devices): activate the cycle, and
carry out the required operations.
6. When work is finished unplug the power supply and turn off the tap which supplies water.
4.3 - Programming
4.3.1 - Selection of the head and regulation of the heating power
In case of a device not connected to any external controller, follow the next procedure to change
the value of the machine's delivered power to the inductor:
Select the wished head pressing, for a moment, the

corresponding pedal (the display will show the indication of
the selected head: H1 = Head 1 ; H2 = Head 2);
H1 99 H1
Head 1 selected,
delivered power = 99%.
Increase or decrease the power value supplied

with the two arrow keys: H1 99 86
Modification of programmed power
From value 99% to value 86%.
29
5
MAINTENANCE
5 - MAINTENANCE
Before performing any maintenance operation on the device, read carefully the Safety instructions - Warnings section of
this manual.
5.1 – Periodical maintenance

In the following table the maintenance periodical operations are indicated together with their
suggested frequency:
Intervention Frequency Operator Procedure

Dry accurately the contact
surfaces of the inductor before
Head contacts drying At each inductor change Operator
mounting it back, to avoid the
joint burning.
The operator shall evaluate the system status and its working capability, according eventually with the maintenance
personnel.
5.2 - Replacement of the support-heating inductor group

If it is necessary to use different inductors for different work processes, we suggest preparing
individual support-inductor groups.
5.2.1 – Heating inductor soldering

The inductor is attached to the heating head support by means of tin soldering. During the
operation , be careful that:
The insulating diaphragm located between the two metal parts should be complete
and should not show signs of burning. If this is not the case, replace it.
the conductors of the heads are dry (to this end use a jet of compressed air)
the tube enters the heating head ducts by at least 8-10 mm;
no traces of tin enter into the conductors of the head (to assure this it is best to
operate with the support tilted downwards at a 40° angle, approximately).
30
MAINTENANCE 5
5.2.2 - Support-heating inductor group replacement procedure
a. Shut off the flow of cooling water to the generator.
b. Disconnect the inductor support 2 to be replaced by removing the four bolts 4. (N.B.: if the
generator is located above the heating head, water may come out of the head: block the
head cooling tubes using clamps, but avoid damage to them).
c. Eliminate the water that has come out, drying the front part of the head 1 well with a cloth
and a jet of compressed air.
d. Remove any remains of dirt from the front part of the head.
e. Check the condition of the O-rings 3 and replace them if necessary: the rings should appear
elastic and not cracked.
f. Check the condition of the insulating diaphragm 7, which can be seen on the front part of the
head: clean it thoroughly and eliminate any carbonised remains. N.B.: if the insulating
diaphragm is deeply carbonised, it is advisable to replace the head.
g. Check the condition of the new inductor support: the insulating diaphragm 6 located between
the two metal parts must be complete and not show signs of burning. Replace it if necessary.
h. Fit the O-rings 3 and fix the support 2 to the head 1, using the bolts 4. Tighten well to avoid
water leakage during operation.
i. Turn on the water again and check that there is no leakage.
1 heating head
2 inductor support
3 rubber o-rings
4 support fixing bolts
5 Inductor
inductor support
6 insulating diaphragm
head insulating
7 diaphragm
Before activating the generator, check that the parts are completely dry. Use a jet of compressed air for this
purpose: the presence of water may cause sparks between the two halves of the inductor support, damaging the
insulating diaphragm 6.
Check that there are no deposits of dirt on the inductor support insulating diaphragm 6 and on the insulating
diaphragm 7 visible on the front of the head: these deposits may cause sparks between the two halves of the inductor
support, damaging the insulating diaphragm.
Use only original CEIA parts.
5.3 - Troubleshooting
The self-diagnosis sistem of the PowerCube notifies the operator in case of malfunctioning by
means of a series of self-diagnosis messages displayed on the display and with an acoustic
signal.
31
5
MAINTENANCE
Display Fault Cause Possible intervention

Water temperature too high. The
display gives the temperature of Malfunction of the Check the temperature of cooling water that have to be
A1 the cooling water, alternating to the cooling unit less than 50° (intervention threshold =65°C)
self-diagnosis message
A2 Tuning failure Contact the technical department of CEIA
Check the presence of water in the cooling unit.

The flow of cooling
A3 Absence of water cooling
water has stopped.
Check the presence of blocking-up in the generator
inlets and outlets.
Short circuit in the

Check the absence of short circuit of lead in wires
inductor
A4 Short-circuit of lead in wire
Small dimensions of the
Increase coil dimensions (see section 6.2.2);
inductor
Decrease coil dimensions.

Decrease at the maximum the distance between the
rims of the head (see section 6.2.2).
Diminish the length (centimeter by centimeter).
Too big dimensions of
A5 Decrease coil size
the inductor
The reduction of the length of the head spouts must be
carried out only in the event that the shape of the
coil cannot be changed for the type of processing
in progress and when the distance between the
lead-in wires has been checked
Possible breakdown of
A6 Power circuit failure
an internal component
Contact the technical department of CEIA
Check the connection between the heads and the

A7 Disconnected head Disconnected head
electronics unit
Insert (between the mains and the heater) a

A10 Line voltage too low
transformer with an input voltage equal to that available
on the line and an output voltage of 220V ~
A11 Line voltage too high
Check and, if necessary, reset the presence of the

three power supply phases and the correct ignition of
The slave unit is not
the three generator units.
correctly connected, is
Slave unit not available In the event that either one or both of the SLAVE units
turned off, or signals a
(PowerCube 64 - Main Unit) presents a self-diagnosis message (A1 or A3), carry out
self diagnosis message
the related tests as indicated in this table.
(A1 or A3).
Check and, if necessary, reset the connection of the
A12 CO11 serial cables between the generator units
Check and, if necessary, reset the presence of the

The SLAVE unit is not three power supply phases and the correct ignition of
Communication failure
correctly receiving data the three generator units.
PowerCube 64 – Slave Unit
from the MAIN UNIT. Check and, if necessary, reset the connection of the
CO11 serial cables between the generator units
Continuous activation
of the generator or
Duty Cycle too high (only on
to Spectacle Frames Line models)
insufficient pause
among consecutive
Start the generator up in an intermittent way
working cycles
The SLAVE UNIT display of PowerCube 64 shows only messages A1, A3, A6, A12.
32
APPENDICES 6
6 - APPENDICES
6.1 – Declarations of Conformity CE

6.1.1 – PowerCube 32/900
33
6
APPENDICES
6.1.2 – PowerCube 32/1800
34
APPENDICES 6
6.1.3 – PowerCube 45/900
35
6
APPENDICES
6.1.4 – PowerCube 64/900
36
APPENDICES 6
6.2 - Shape and position of the inductor

In order to carry out the soldering as quickly and efficiently as possible, we recommend that these
indications be followed:
1. Distance between inductor and pieces to be soldered: it should be remembered that the
transfer of heat between these two elements takes place by means of magnetic induction; it
is therefore advisable to keep the space between the coil and the pieces to be soldered to a
minimum.
2. Shape of the coil: The shape of the coil must follow the outline of the soldering zone. It is
also advisable not to use a coil whose dimensions are excessively large.
6.2.1 - Flow of Cooling Water

For correct operation the flow must not be less than the minimum for each model as stated in the
“Technical Characteristics” section of the manual. The use of inductors constructed with tubes of
reduced diameter or of a shape which creates constriction (severely reduced dimensions or sharp
bends) may cause a decrease in the flow sufficient to result in inductor overheating. If process
requirements necessitate the use of this type of inductor, the water input pressure must be
increased, remaining within the limits stated in the “Technical Characteristics” section.
The suggested pressure, corresponds to the difference between the input pressure and the output
one of the generator.
Remove eventual flow slowing down of the water output.
There follow some examples of the positioning of the parts:
3
1 Soldering point
1
2 Heating coil
2
3 Piece to be soldered
1
3
Distance between soldering
x point and coil
2 0,1 - 0,3mm
1 1 x
3
3
x
2
2
INCORRECT POSITION OF THE COIL CORRECT POSITION OF THE COIL
(induttore troppo lontano dal punto di saldatura)
37
6
APPENDICES
6.2.2 - Dimensions of the heating inductor

The use of an inductor in the correct shape allows the apparatus to operate in the optimum manner
and to obtain the best quality of the product. It is recommended the use of silver-plated copper
tube.
In general, the number of loops is a function of the dimensions of the inductor:
Loop diameter Recommended number of loops Examples
> 8÷9mm Single loop ø1.8mm

ø9mm
20mm
< 8÷9mm Two loops ø7mm

ø1.8mm
In general, the shape of the inductor depends on various factors: the type of metal the piece is
made of, the shape and size of the piece and so on. The figure illustrates two examples of
inductors for special use.
Inductor shape Type of process Result
10mm
ø1.8mm
25mm
20mm
10mm
ø1.8mm
30mm
Inductor test
To check that the dimensions of the coil are correct, switch on the generator with the piece being
worked in position: if the self-diagnosis system does not give either the A4 (coil too small) or A5
(coil too large) message, the dimensions are correct.
Inductor for large pieces

If the piece being worked is large, it is possible to use a
single coil 2 of a suitable size whilst reducing the length of 1
the adductors 1 so as to keep the total value of the
inductance within the operational limits of the equipment.
2
38
APPENDICES 6
High-power inductor with continuous activation
For heavy work (high power and continuous activation) the
use of the short adductor is recommended; in this case, use
tubes with 2,5-2,8mm diameter.
29 ø3
50
65
6.2.3 - Dimensions of the heating inductor

The use of an inductor in the correct shape allows the apparatus to operate in the optimum manner
and to obtain the best quality of the product. The use of silver-plated copper tubing is
recommended.
The illustration shows some examples of inductors in general use:
15mm
ø5-8mm 8mm
ø1.8mm 20mm ø1.8mm
25mm
6.2.4 - Optimisation of the generator efficiency with small dimension inductors

In case the heating inductor has small dimensions, for space and welding reasons (loop diameter
lower than 8 mm), the efficiency of the machine can be optimised and the heating times reduced,
by spacing the adductor (1 ) out. It is necessary to have a distance of 2,5 mm or more between
the two coil tubes. Such distance secures an improved heating power and consequently a reduced
heating time. This operation, which is normally not advised for classical generators gives to the
PowerCube generator, a higher speed welding outcome.
2.5mm
1 1
2 2
<8mm <8mm
WRONG! CORRECT !
In case of excessive removal of the adductor (1), the generator will utter an alarm signalling and
they will have to be brought nearer (however, at a minimum distance of 2,5mm).
If during the operation the indicated heating power will be smaller than the adjusted power value
(for example 99%) it is important to increase the distance of the two inductor tubes until the
adjusted value (99%) will be shown during the heating process.
39
6
APPENDICES
6.3 - Construction of equipment, clamps, and matrixes

6.3.1 - Materials to use
It is important to use special materials in the construction of the various parts used in the soldering
process (such as clamps, support matrixes, etc.):
- Inside the heating coil do not use any metals; use only ceramic materials.
- Outside the coil, brass, steel or aluminium may be used, at a distance of at least 2mm.
- Do not under any circumstances use iron near the heating coil.
6.3.2 - Dimensions of the parts

The supporting and fastening parts of the pieces to be soldered, if manufactured in metallic
material (steel or brass), should be of limited dimensions so as to avoid possible energy absorption
on the part of the heating coil. The illustrations below show some examples of construction.
> 2mm > 2mm
2
2: heating coil;
4: external supporting parts
(brass, steel or aluminium);
4 5 4 5: internal supporting part
(ceramic)
Supporting part too big
1: soldering point;
3: pieces to be soldered;
4: supporting part (brass, steel
Supporting part correct or aluminium)
40
APPENDICES 6
6.4 - Use of anti-oxidizing gas

With the aim of improving the quality of the Soldering
1
soldering, it is useful to use distribution point
valves for the diffusion of anti-oxidizing
gas in the soldering area. 2 Coil
Pieces to
These diffusers should be as close as 3 be
possible to the heating coil and to the soldered
piece being processed, so as to create, Gas
4
during the soldering, an oxygen-free diffusers
"chamber".
End part
The end part of the diffusers should be of the
constructed in non-metallic material (for diffuser
example, teflon), in the event that such 5 in non
parts come very close to the coil. metallic
material
(teflon)
There follows an example of an installation
with gas diffusers.
6.5 – Control via RS232 serial interface

The generators of PowerCube family, can be managed through the use of a serial line, using a
Terminal or a Personal Computer.
6.5.1. Setting of the Terminal

Connect the RS232 port of the For this connection a serial communication cable (CEIA
PowerCube to a terminal configured with code 19623) may be used).
the following line parameters:
Power Cube Personal Computer
Baud rate : 9600 3 2
parity : no parity 2 3
data bit :8 5 5
stop bit :1
flow control : non 9p 9p
6.5.2. Starting of the connection

On the terminal keyboard, press "Ctrl-Z": on the screen the character ">" will appear (should it not
appear, repeat the operation).
41
6
APPENDICES
6.5.3. Commands
The commands available are the following:
Syntax Description
H1 <CR> It activates the head 1 of the generator
H2 <CR> It activates the head 2 of the generator
S1 <CR> It stops heating at head 1.
S2 <CR> It stops heating at head 2.
Reading of the working power pre-selected for the heating head 1: a value from 10
P1<CR>
to 99 is displayed which has to be intended as percentage of the maximum power.
The working power for the heating head 1 must be set at xx, being xx between 10
P1=xx<CR> and 99. The pre-selected power can be varied only when the heating head is not
activated.
Reading of the working power pre-selected for the heating head 2: a value from 10
P2<CR>
to 99 is displayed which has to be intended as percentage of the maximum power.
The working power for the heating head 2 must be set at xx, being xx between 10
P2=xx<CR> and 99. The pre-selected power can be varied only when the heating head is not
activated.
Reading of the power supplied: a value from 10 to 99 is displayed which has to be
PW<CR> intended as percentage of the maximum power or -- if none of the two heating
heads is activated.
_RO<CR> Reading of the external signalling relais status
Setting of the operative mode for the external signalling relais: Possible values are
AL and ON. with _RO=AL (default), the relais indicates the generator alarm status,
_RO=xx<CR>
opening the circuit in case of alarm or generator not powered. with _RO=ON, the
relais closed the circuit in presence of generator output power.
Reading of the POWERCUBE state : in the event that none anomalous situation is
present OK is the answer displayed, otherwise a diagnosis code Ax will be
SC<CR> displayed, having x between 1 and 12 showing an anomalous situation. See on
section MAINTENANCE of the PowerCube instruction booklet for the codes
meaning comprehension.
in case of wrong syntax, out of range parameter or unrecognised command, the controller will show the message: ???
42

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03 – Installation, Use and Maintenance Manual - PowerCube 32/45/64

Document Revision Date Software version

Rev. Date Author Reference Description

Customer Satisfaction Report

Thank you for your kind interest and co-operation.

1 - SAFETY INSTRUCTIONS - WARNINGS

1.1.2 – Installation warnings

1.1.3 – Use warnings

1.2 – Residual risks

- In particular, direct or indirect contact with

1.3 – Correct and Forbidden use of the device

1.3.2 –Forbidden use of the device

2.1 – General description

2.2 – Functional Diagram

Block diagram of a PowerCube 32 soldering station.

1 Alphanumeric display which shows the functioning messages

2 Two push-button for the regulation of the power delivered by the

5 Power supply cable

6 The connectors and terminals necessary for the installation of the

the two central electronics units include a power supply

Heating head HH10 (* refers to model 32/1800)

Heating head HH15

2.3.4 - Available adductors

2.3.5 - Adjustable supports for heating heads

Standard adjustable support ES25

62,5 150 123

Adjustable support ES25

Adjustable precision support for heating head ES35L/R

adjustable precision support ES35L

2.3.6 - Activation pedal

2.4 - Safety devices and warning labels

IP Protection degree The device has a protection degree IP20

Options Part Number

Accessory Part Number

Activation pedal 3457

1000x700x1370 working desk

Standard adductors kit - 150mm

- Assembled 1800 series adductor - 100mm 14123

- Assembled short adductor - 70mm 3461

ES25 heating head support 3454

ES35 precision heating head support 9252

2.6.1 – Heating head HH10

Accessory Spare part

Full HH10 heating head

1.5 m cable length PWH-10-XX-15/900

3.0 m cable length PWH-10-XX-30/900

4.0 m cable length PWH-10-XX-40/900

Custom cable length PWH-10-XX-CC/900

2.6.2 – Heating head HH11

Accessory Spare part

Full HH11 heating head

1.5 m cable length PWH-11-XX-15/900

3.0 m cable length PWH-11-XX-30/900

4.0 m cable length PWH-11-XX-40/900

Custom cable length PWH-11-XX-CC/900

2.6.3 – Heating head HH15

Accessory Spare part

Full HH15 heating head