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OPERATION AND
MAINTENANCE INSTRUCTIONS
30 & 45 kW Induction Heating Systems
100kHz ES Models
PRECISION
INDUCTION HEATING EQUIPMENT
File Name 801-9335-00.doc
Part Number 801-9335-00
Revision Rev NECN# 1209-10
By Dan King
Approved
Date 9/10/2012
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Introduction 3
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801-9335-00.doc
Table of Contents
1 Introduction ...........................................................................................................................51.1 Safety Considerations......................................................................................................6
1.2 Front Panel.......................................................................................................................7
1.3 Service Panel ...................................................................................................................8
1.4 Installing Your System..................................................................................................11
1.5 System Cooling Requirements ......................................................................................15
1.6 Safety Means and Connections .....................................................................................17
2 How your EKOHEAT Works ............................................................................................19
2.1 Display, Control ............................................................................................................19
2.2 Detailed EKOHEAT Operation.....................................................................................25
2.3 Navigation .....................................................................................................................272.4 System Configuration....................................................................................................27
2.5 Files (Heating Profiles)..................................................................................................34
2.6 Workhead Configuration...............................................................................................36
2.7 System Status Page........................................................................................................37
2.8 Interpreting Messages....................................................................................................37
2.9 Equipment Maintenance................................................................................................39
2.10 Through-Heating ...........................................................................................................40
3 Customizing Your EKOHEAT ..........................................................................................413.1 Rear Panel Connections.................................................................................................41
3.2 Optional Pendant ...........................................................................................................47
3.3 Serial Control.................................................................................................................49
3.4 RF Tap Adjustment .......................................................................................................59
4 Technical Information.........................................................................................................63
4.1 Mechanical ....................................................................................................................63
4.2 Electrical........................................................................................................................63
4.3 Environmental ...............................................................................................................65
4.4 Contact Information.......................................................................................................66
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Introduction4
AMBRELL
Notes:In this manual, these symbols indicate:
a step in a procedure manual sections
lighted indicators on theequipmentA notice that requires yourspecial attention; may pertain tosafe operation of the equipment
A notice that requires your specialattention due to potential hazards topersonnel or property
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11 IInnttrroodduuccttiioonnYour EKOHEAT is a solid-state induction heating system that converts 3-phase linevoltage to a maximum terminal output (per model, see 4.2) over a range of radio
frequencies (RF) and voltages. This energy is delivered to a parallel-resonant circuit -
including your coil - where a precisely controlled magnetic field is created around your
work-piece.
EKOHEAT uses a special sensing technology enabling optimum control of your
process; precise frequency registration under varying load conditions results in
increased precision in heat control and times-to-temp.
Special featuresYour EKOHEATsimplifies and improves your heating results with: efficient heating of many part geometries
agile operation for repeatable, reliable results
touch-pad interface for control and programming
backlit LCD simultaneous display of important data
electrically isolated remote water-cooled work head
5-language display suite
The power from your supply can be controlled:
manually from the front panel
remotely by your signals provided to the rear panel remotely through the RS485 serial communication port
from one of ten 10-step heating profiles you specify
UnpackingYour EKOHEAT induction heating system has been carefully packed to arrive at your
facility in good condition.
We suggest you inspect the shipping carton in the presence of the carrier when the unit
arrives at your facility. Look for dents, crushed corners or torn cartons.
YOU MUST REPORT ALL DAMAGE DIRECTLY TO THE CARRIER. Check to see that all the parts we shipped arrived at your plant:
EKOHEAT power supply
RF power cable(s)
remote work head with control cables
optional coils and/or equipment
reference coilIf you note damage, do not discard any of the exterior packing cartons; retain the
carton(s) so that the carrier's claim agent may inspect it. We will assist you in filing a
claim against the carrier should it be necessary to do so.
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11..11SSaaffeettyy CCoonnssiiddeerraattiioonnssYour EKOHEAT uses RF energy to raise the temperature of your work-piece. Most of
this RF energy is transmitted into the work-piece and some is transmitted into the air.
Physical RisksDuring the HeatOn cycle, high RF voltages are present at your work-coil. There are
several risks, which we instruct you to protect against:
We recommend construction of an interlocked mechanical barrier around the work
head in order to minimize all of these risks. Ambrell work heads are fitted with theaccepting hardware for your sheild scheme.
Safety CircuitThe EKOHEAT safety circuit includes:
(provisional) interlock switch from the workhead (TB2:87Interlock)
your (optional) N.C. E-STOP switch (TB1:87)Your (optional) switch can be installed at the terminal block
(TB1:87; factory-jumpered); when your switch opens, all output
power ceases.
After the safety issue has been resolved and the switch has been re-closed (safe state), a front-panel or rear-panel RESET is required to
clear the safety circuits. Your E-STOP switch must be an isolated (dry) contact, capable
of switching 0.1Amin @24Vdc.
Equipment response to opening of any of these switches is the same.
7 8 9 10
E-S
TOP
IN
-+ -+
E-S
TOP
OUT
TB1
High Temperatures: take steps to prevent personal contact with the work-piece you are heating. Severe burns can result from contact at these
temperatures!
RF Voltages: we recommend that you provide protection against personalcontact with the work-coil when it is energized (HeatOn).
Induction burns: the energized work-coil causes nearby metals to becomeheated; DO NOT APPROACH ENERGIZED WORK-COIL WHILEWEARING OR CARRYING METAL OBJECTS!
Pacemakers : high magnetic fields may be present. Pacemakers or othersimilar implanted devices may be adversely affected and the result could bedangerous or fatal.
Electrical installations must be made by a qualified electrician and must conform toapplicable safety codes.
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If your EKOHEAT was purchased with an E-STOP switch installed on the front panel
(optional), E-STOP OUT will be configured to re-transmit the state of this switch. This
contact can be used in your larger system.
11..22FFrroonntt PPaanneell
Touch-pad & Display
Status LEDs indicate what your EKOHEAT is doing
LCD display provides operating information, navigation/programming prompts
Soft Buttons permit selections of features displayed on screen
Navigation buttons are used to program and control the unit
START & STOP buttons support front panel control of heating
Disconnect/circuit breaker switches line voltage to system
When this safety circuit trips, a contactor inside the equipment removes linevoltage from the power conversion portion of the equipment, halting RF poweroutput, but the disconnector switch, fuses, EMI filter and line-side of the contactorremain live and hazardous until the customer-supplied disconnect has beenopened by you.Never operate this equipment with the covers removed!
START
Navigation
Display
Status
STOP
Soft Buttons
Note: figures displayed on your system may vary from those shown here
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11..33SSeerrvviiccee PPaanneell
The rear panel of your EKOEAT places all electrical access behind easy-to-remove
service covers: mains and I/O connections are found behind the two upper service
covers and access to the RF transformer taps is found behind the lower service cover.
I/O access
Cooling water ports
Mains cable port
RF cable ports
Mains access
Transformer cover
PE Ground
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I/O service cover (TB1 & TB2)Behind the I/O service cover (left) is where all electrical connections are made for all
input and output signals (3).
outputs to your devices
an optional pendant or PLC controller
signals from your analog controller
external flow-switches from the work head
serial port; your RS-485 hardware connection
TB1 (upper) and TB2 (lower) plugs are removable for convenience in servicing or
moving your equipment. Cable clamps can be used to secure your I/O wiring .
Mains service coverBehind this grounded cover (right), your power supply requires 3 AC power from
360 to 520 Vrms. Cable entry to this service area is provided via a plastic strain-reliefbushing. Your 1.5 (38mm) metallic bushing and conduit can be attached at the line
port.
Your mains power cable is routed from your (recommended) fused disconnect to the
line-side connections at the bottom of the 3x fuse holder. We have selected semi-
conductor fuses (4.2) here for their rapid-action.
The protective earth ground (PE) connection is made at the indicated terminal.
An additional protective earth (PE) ground connection is made at the terminal on
the bottom-right corner of the rear of the enclosure (shown, previous page)
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RF cable ports
The RF energy created by the EKOHEAT is directed to the work head via the RFcable(s), (1.4). Friction strain-relief bushings are provided. Your 1 (25mm) bushing
and conduit can be attached at the RF port. The RF cables are routed from the work
head to the power supply.
Transformer coverThis indexed cover must be removed (with all power off) to adjust transformer taps as
directed by the display screen or by our service personnel. Cover must be in place to
satisfy the safety circuit. Any changes to the selected tap must be recorded at the front
panel (3.4).
Cooling water portsYour EKOHEAT uses circulating water to cool internal components; inlet and outlet
connections for the power supply are made at these rear panel ports. Internal flow-
switches are used to interrupt heating operations if this flow is inadequate. Temperature
sensors are used to reduce heating if the internal temperature rises too high
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11..44IInnssttaalllliinngg YYoouurr SSyysstteemmYou may elect to use Ambrells Service Department to install your EKOHEATequipment. Our field service engineers can be scheduled in advance to arrive at
your facility to assure that your equipment is correctly and efficiently installed. Prior to
a scheduled installation, we ask that you put your system in place and connect your
factory power and water facilities. Please call us at:
USA UK Europe/Middle East+1.585.889.9000 +44 (0)1242 514042 +31 548 659 044fax +1.585.889.4030
Site Requirements
Take these factors into consideration as you determine where to install your system: Availability of 3 AC power
Proximity to the work area (RF power cable length)
Availability of cooling water and drain
Sufficient service area around the equipment
The power supply is mounted on a pair of c-channel runners, providing clearance under
the equipment as well as fork-lift access from the front or rear. The runners are
removable if your installation requires it.
Caution: Lifting hazard; may result in injury; lift unit from bottom using fork-lift orother mechanical assist. Do not lift equipment by side handles
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Access to the Power Supply
Power Supply and Cabling(Refer to your Schematic Drawings)
Your EKOHEAT system accepts 3 line-voltages from 360 to 520 Vrms. The mainsfuse selection anticipates this supply voltage. See 4.2 for replacement mains fuse
information.
Plan a 5-wire routing forthree phases and two protective earth grounds.
DisconnectWe recommend that you install a fused disconnect switch (not supplied by Ambrell) in
the branch circuit supplying the equipment. Base your selection of fuses on the
equipment nameplate data.
Determine correct disconnect fusing and wire gauge
Place the disconnect near the power supply and in sight of the operator
ConduitWe recommend that the AC power and RF wiring to your power supply and work head be run
through solid metallic conduit (EMT). To ensure the highest levels of electromagnetic
immunity and to effectively limit electromagnetic emissions, solid conduit is required. For AC
power cabling, 1.5 (38mm) and for RF cabling, 1 (25mm) conduit cutouts are provided at the
rear panel.
If you elect to use a smaller conduit size for your AC wiring, use a reducer to accomplish
this conversion at the rear panel
Mains power (conduit)
The equipment requires two connections to protective earth ground. Failureto connect both protective earth grounds can result in a potentiallyhazardous condition if a single-point failure to earth ground accidentallyoccurs. Do not omit this step!
Electrical installations must be made by a qualified electrician and mustconform to applicable safety codes.
Your EKOHEAT system uses and produces high voltages! Routineconfiguration by the User does not require access to internal components.Only trained or guided service persons are authorized inside the Supply.Portions inside the Supply remain energized and hazardous after the ACPower Switch is off. Always turn off the customer-supplied fuseddisconnect before attempting any service.
Caution: Stored electrical charge can persist at internal terminals for severalseconds following disconnection of AC power! Allow 60 seconds after
disconnection before touching or servicing internal components.
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Use a Philips screwdriver to loosen the 3 screwsthat secure the mains service cover; remove mains
service cover
Attach and secure the conduit and bushings(between the fused disconnect and power supply)
required for your installation
Route the cable from your fused-disconnect to themains cable port of the power supply. Base your
selection of wire gauge on the equipment
nameplate data (2AWG or ~33mm2 max)
Strip the insulation to (18mm) on each of thewires of your cable (3 phases,& 2 GNDs)
Apply ring lug to one of the ground wires and
secure it to the post provided (PE). Using Philips screwdriver, ensure L1-L3 (Line)terminals of the 3x fuse block are fully opened.
Insert the three power wires into the 3x fuse block
line-side (shown, L1, L2, L3) and secure. There is
no polarity to the three phase connections.
Replace the mains service cover; move to the nextstep.
Apply a ring-lug to the second protective earth ground wireand secure it to the second post provided (PE)
PE
L3L2L1PE
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RF cabling (using conduit)You will install two cables for your EKOHEAT. For every model, there is one cable
which has an additional sense wire-pair (labelled X1, X2) and a drain wire. Thesesense wires carry signals that enable your EKOHEAT to adjust its output to conditions
at the workhead.
Attach and secure the conduit andbushings between the work head and
power supply as required for your
installation
Route the RF cables through the conduitfrom the work head to the RF ports at the
rear of the power supply
Remove the transformer cover at the rearof the equipment
Remove the right-side cover (16 philipsscrews)
Route the RF cables to the terminals X1,X2, as shown (observed labeled
polarity). Use nut driver to secure
cable wires to terminals.
Observe labelling and color-coding,attach the sense wire-pair to the
appropriate X1, X2 terminal pair on
the circuit board, shown right(factory-indicated for your
application; do not change without
factory guidance)
Attach and secure drain wireconnections from RF cable(s) to
stud, shown.
Replace the transformer cover;record Tap# (3.4)
Replace the right-side coverSee 3.4 for Tap instructions
X2
X1
The RF power cable is constructed to specific requirements; it is a specializedcable. Do not substitute any other cable in its place. Failure to observe this cautioncan result in severely diminished performance and in cable over-heating. CallAmeritherm to replace or re-specify the RF power cable.
Drain
Power
Sense
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11..55SSyysstteemm CCoooolliinngg RReeqquuiirreemmeennttssYour EKOHEAT system uses
circulating water to cool the internal
components; you must provide this
service now. In the process of heating
your work-piece, the current flowing in
the system and work head tank circuit
heats the components, too. It is
necessary to dispose of this excess heat
to prevent damage to the components of
the induction heating system.
Power supply cooling waterPower supplies are equipped with two 1/2 quick-connect fittings: inlet right, outlet
left.
Establish a cooling water source capable of 2.5 gal/min@40psi (9.5 l/[email protected] bar)
differential pressure (complete system) See 4; ensure cooling water minimum flow Install a shut-off valve upstream and convenient to the power supply Provide water supply and drain using OD tube (plastic or copper)
Install a pressure regulator and a particulate matter filter (both non-ferrous) inthe supply of your cooling water. Use copper, rubber hose, stainless steel or PVC tubing. Do not use ferrouspipe for th is system; it can lead to serious equipment damage!
If Glycol is employed in your cooling water please be aware that
The Glycol must not be automotive grade but rather Inhibited EthyleneGlycol specifically formulated to protect brass, copper, and copper alloys.(Dimplex has a product called K-Kool-E and Dow chemical has a line) Other
types of anti-freeze or anti-rust agents can be conductive and can causecatastrophic failure of your equipment.
The maximum glycol concentration should not exceed 20% as coolingcapacity is limited to 82% capacity (see chart). Concentrations greater thanthis can catastrophically impair the cooling of your power supply, workheadand coil.
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Work head cooling waterEach work head provides a means of directing fresh water into and through the
components, enabling the water to pick-up the excess heat and transfer it, either to drain
or to cooling to be recycled back to the
equipment.
Follow these important restrictions:
Establish a cooling water source capable of40psi (2.8 bar) differential pressure across
the system.
See 4 for important cooling water minimumflow figures
Install a shut-off valve upstream andconvenient to the work head
Complete the plumbing to the work head.Note location of INLET and OUTLET each
for CAP and for COIL; flow must follow
these orders.
Provide COIL water supply and drain using OD tube (plastic or copper)
Provide CAP water supply and drain using 1/2 OD tube (plastic or copper)
Flow monitoring
The amount of water flowing through your work head must bemonitored, since inadequate flow or loss of cooling water can result
in damage to the equipment. Flow-switches are always included as a
part of the equipment, providing two-wire (N.O.) signals to the power
supply for monitoring. When flow is adequate, the switches close,
when flow falls off, the switches open and the power supply senses it,
halts RF power and indicates Fault status on the display (see 2.8
for details)
Route the capacitor flow-switch wires [FLS3 140:141] toTB2:64 at the power supply. It is not necessary (or
recommended) to include them inside the RF cable conduit. Route the coil flow-switch wires [FLS4 142:143] to TB2:65 at the power
supply.
If you omit these connections, or if cooling flow is inadequate, your equipment cannot
Heat (see Fault).
Two flow-switches are mounted inside the power supply to assure adequate cooling
water to the internal components of the power supply. No connections are required by
you, but Faults will arise from inadequate flow to the power supply.
WORKHEAD
+
4 5 6 7 8
+ -- +
FLS
3[140]
FLS4[142]
GND[141,143]
TB2
INTLK
[146]
INTLK
[147]
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11..66SSaaffeettyy MMeeaannss aanndd CCoonnnneeccttiioonnssYour work head uses RF energy to raise the temperature of your work-piece. Most ofthis RF energy is transmitted into the work-piece and some is transmitted into the air.
Physical risksDuring HeatOn, high AC voltages are present at your work-coil. There are several
risks, which we instruct you to protect against:
Interlocked barrierWe recommend construction of an interlocked mechanical
barrier around the work head in order to minimize all of
these risks. Ambrell work heads are fitted with the accepting
hardware for your sheild scheme. Use a normally-open
switch which closes only when the barrier is fully closed. AFaraday cage can double as a mechanical barrier!
Remove the jumper that has been installed at E-STOP IN Direct the wiring from your interlock switch (COM
N.O.) to E-STOP IN TB1:87
Connect the switch wiring to these points. There is no polarity.
With this wiring in place, the power supply cannot become Ready until the barrier is
closed and RESET has been enacted. Once heating, the RF output will shut down
immediately if the barrier is opened. This input is always enabled.
This input can be left to the factory-jumpered configuration if not used.
High Temperatures: take steps to prevent personal contact with the work-piece you are heating. Severe burns can result from contact at elevatedtemperatures!
High RF Voltages: we recommend that you provide protection againstpersonal contact with the work-coil when it is energized.
Induction burns: the energized work-coil causes nearby metals to becomeheated; DO NOT APPROACH ENERGIZED WORK-COIL WHILE WEARINGOR CARRYING METAL OBJECTS!
5 6 7 8 9 10 11 12
E-STOP
IN
-+ -+ -+ + -
E-STOP
OUT
AN:IN1
TB1
READY
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Faraday cageIf, during HeatOn, you experience unacceptable interference with surrounding
equipment (AM radios, Hall-effect switches, etc.) you can reduce this interference byconstructing a Faraday cage around your work head.
This can be nothing more than a metal box that completely surrounds the work head
and coil. It can be made of copper or aluminum and may be perforated (.125 to .250 or
3 to 6 mm). The RF energy that would otherwise go into the air is conducted over the
surface of the cage. Providing a ground connection for the cage is not necessary but
may provide an additional measure of RF suppression.
At the frequencies your equipment operates, adequate suppression can result if the cage
is constructed of perforated UNPAINTED Aluminum, 14 to 16 gauge. Follow these
construction tips: Do not use steel for any portion; it can be heated by your work-coil.
Allow 2 (5cm) or 2x coil diameter between the work-coil and cage.
Make sure there are no open seams or cracks
Make good connections where the conduit enters the cage.
Avoid the use of PAINT or anodizing where panel surfaces meet; theseare insulators and they defeat the cages purpose.
Safety CircuitThe EKOHEAT safety circuit includes:
(provisional) interlock switch from the workhead (TB2:87Interlock)
your (optional) N.C. E-STOP switch (TB1:87)Your switch can be installed at the terminal block (TB1:87; factory-
jumpered); when your switch opens, all output power ceases.
After the safety issue has been resolved and the switch has been re-
closed (safe state), a front-panel or rear-panel RESET is requred to clear
the safety circuits. Your E-STOP switch must be an isolated (dry)
contact, capable of switching 0.1Amin @24Vdc.
Equipment response to opening of any of these switches is the same.
If your EKOHEAT was purchased (optional) with an E-STOP switch installed on thefront panel, E-STOP OUT will be configured to re-transmit the state of the E-STOP IN
port for use in your larger system.
7 8 9 10
E-STOP
IN
-+ -+
E-STOP
OUT
TB1
When this safety circuit trips, a contactor inside the equipment removes line voltagefrom the power conversion portion of the equipment, halting RF power output, butthe fuses, disconnect switch, EMI filter and line-side of the contactor remain live andhazardous until the customer-supplied disconnect has been opened by you.Never operate this equipment with the covers removed !
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22HHooww yyoouurr EEKKOOHHEEAATT WWoorrkkssWhen you select HeatOn, (details, next page) this equipment concentrates an
electromagnetic field within the coil diameter. When you put your metal part into the
coil, this field causes internal electric currents in your part. Friction from these currents
heats your part.
With HeatOn, both Setpoint (your selected output voltage level; higher means hotter)
and Output Level (actual power or voltage delivered to your part) are displayed.
Typically, the Output Level is highest when your part is in the coil and it returns to a
lower level when you remove your part. (For detailed explanations or to understand
operation that is not typical, see 2.8)
22..11DDiissppllaayy,, CCoonnttrroollThe EKOHEAT concentrates control and status information within this panel:
START/STOPto initiate heating from frontpanel
Soft Buttonsto select specific features
Displayed dataOUTPUT:
(V or kW when heating)SETPOINT:required output levelTIMER:count-up, count-down orcontinuousFREQUENCY: of output
START STOP
Select Adjust
HomeSoft Buttons
Ready HeatOn Limiting Fault
Note: figures displayed on your system may vary from those shown here
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Simplest exampleIn this example, you heat the part at 200V Setpoint.
Do this... Observe... open water-valve for the system check drain; ensure water is flowing check the work-coil ensure there is no work-piece yet check condition of (any) safety barriers
or limit switches
all safety devices are clear, electrically closed
turn on EKOHEAT Ready LED (is ON)
Use Select buttons to highlight SETPOINT or TIMER and to scroll through on-screen lists.
note display: ensure Setpoint is selected (example)
Use Adjust buttons to change on-screen figures such as SETPOINT, TIMER,etc.
press Adjust until: 200V
secure unheated part in coil part not contacting coil; do not hold
0V
200V
0ms121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT 21
Note: figures displayed on your system may vary from those shown here
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Timed heatingIn this example, you heat the part at 200V output for 10 seconds. EKOHEAT halts
heating when the Timer duration you set has expired.
Press START to begin induction heating.Press STOP to halt induction heating
press START HeatOn, Ready press STOP Ready only remove heated part from coil avoid contact with heated portions
Do this... Observe... use Select buttons, highlight Timer O s press Home button note T subscript on display use Adjust buttons until: 10s secure unheated part in coil part not contacting coil; do not hold
press START
HeatOn,
ReadyReady only, after timer expires remove heated part from coil avoid contact with heated portions
201V
200V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
3
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Display features
OUTPUTActual voltage at the output when HeatOn. Larger values result in faster heating or hotterparts. With the pointer () on SETPOINT, you can increase or decrease the setting with the/ buttons.
EKOHEAT works to match the RF output to this setting when the RF power is on ( HeatOn).Use to toggle between Volts and kW
SETPOINTThis is your desired output setting. Use to locate the pointer at SETPOINT, then increaseor decrease the output setting with the/ buttons.EKOHEAT works to match the RF output to this setting when the RF power is on ( HeatOn).
568V568V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
568V
568V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
568V
568V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
FREQUENCYThis is the RF output frequency when HeatOn. It is the resonant operating frequency and isthe result of your coil in combination with the work heads internal capacitance.When Ready after first turning on the EKOHEAT, the idle frequency (4.2) is displayed.During the first heat cycle (HeatOn), the frequency value shows you what the resonant(most efficient heating) point is. When the heat is turned off, the display shows the lastresonant frequency. Sometimes, you may see that the output frequency approaches eitherend of the operation range of EKOHEAT (4.2) and the display advises you to increase ordecrease capacitance. Please call Ambrell for assistance should this happen and we willsupply you with the appropriate capacitors.
Note: figures displayed on yoursystem may vary from those
shown here
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Customizing Your EKOHEAT 23
Precision Induction Heating
801-9335-00.doc
568V
568V0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
T
TIMER
Note T , timer or C , count up displayed near arrow; Press to toggle the cycle-timedisplay mode
T Untimed: heat-cycle is not timed, display doesnt change
Adjust the display as shown (0ms), T ; press START: heating continues until STOP signal is received. Display TIMER doesnt change.
T Timed: heat-cycle time is displayed, decrements to zero, heating stops Use to place the pointer at TIMER, then increase or decrease this setting to valuesbetween 10 milliseconds and 9999 seconds with the / buttons; press START: heating continues for the duration of your setting or until STOP signal isreceived. Displayed TIMER counts down.
C
Counter: accumulated heat-cycle time is displayed press START: heating continues until STOP signal is received Displayed TIMER counts up. The duration of the last cycle is displayed until the nextSTART signal or until TIMER function is selected
568V
568V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
Load MatchingWhile heating, EKOHEAT reveals how power is being transferred to your part. Your loading isevaluated to determine matching (%MATCH) for the RF tap selection in use. 100% MATCHis ideal.Matching can be improved through RF tap selection (3.4)Values below 25% are not displayed. %MATCH over 100% is possible and may result inoutput limiting 2.2
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AMBRELL
Messages
In the upper center of the display, EKOHEAT reveals any corrective messages pertaining toits operation or status:Flow switch trips; inadequate water flowsafety switch trips;see 2.8 for full list of Messages and recommended corrective actions
Power & TemperatureIn the lower center of the display, the output is shown in alternate units (kW if Volts used onmain display, vice versa).The temperature of the enclosure air and heat sink are displayed below that. EKOHEAT cuts-back output power if these temperatures exceed a factory-set maximum.
568V
568V0ms
121kHz
PWR 0kW%MATCHVMAX = 977V
TEMPERATUREAir 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
568V
568V
0ms
121kHz
PWR 0kW%MATCHVMAX = 977VTEMPERATURE
Air 77FHsnk 73F
SYSCFG
WHDCFG
SYSSTAT
MESSAGES:Displayed whenfault conditions aretripped
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22..22DDeettaaiilleedd EEKKOOHHEEAATT OOppeerraattiioonnThis section details how to: interpret the Status LEDs
use touch panel features
understand system Faults and Advisories
Status LEDs
ReadyEKOHEAT is waiting to heat; no faultsdetected
HeatOnSTART command received, outputtingpower per settings. It may be possible toachieve a more efficient configuration,though output is within acceptable margins.
LimitingEither the Voltage, Power or Temperature
values have reached their maximum limits.See 2.8 for further information.
FaultHeating interrupted; fault detected;correction required. Read display forinformation about the Fault
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Customizing Your EKOHEAT26
AMBRELL
Touch-panel features
Select
Use Select buttons to highlight SETPOINT or TIMER and to scroll through on-screen lists
Adjust
Use these buttons to adjust on-screen figures such as SETPOINT, TIMER,etc.
HomeUse this button to take you back to the Home screen.With the Home screen displayed, highlightSETPOINT; then press this to display workhead VOLTS or kWTIMER; then press this to display Timer (T) or Counter (C)
START
STOP
When starting the unit from the front panel, use these buttons to (de)activateheating.
Press START to begin induction heating. HeatOn (LED) shines and the
display is updated with operating data. START operates only when HOMEscreen is displayed
Press STOP to halt induction heating (2-button start type). The unit returns toReady state. (STOP signal from front or rear panel always halts inductionheating)
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22
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Normal operation is from the Home screen, where you: adjust setpoint and timer
turn RF power on and off
switch displayed units or
select soft-button functions:
Select the soft-button functions to enable:
SYS CFG, (System Configuration); use this interface to adjust the way yourEKOHEAT operates
WHD CFG, (Work head Configuration); use this interface to inform the
EKOHEAT about the configuration of the attached work head and RF tapsettings. These figures are factory-set for your system; you may need to adjust
here to improve output efficiencies or for future changes in work head
configuration.
SYS STAT; System status shows operating firmware numbers
22..44SSyysstteemm CCoonnffiigguurraattiioonnSeveral operating characteristics of the EKOHEAT can be changed to suit your process
needs.
While your system is Ready (not heating), press the SYS CFG soft-button:
The first configuration page presents these characteristics.The asterisk indicates which characteristic is selected;
use Select / to move to the desired characteristic. useAdjust / to toggle the value for the characteristic select NEXT PAGE for additional configurations
These characteristics are explained in the next tables:
Note: figures displayed on your system may vary from those shown here
BACK
NEXTPAGE
FILES
SYSTEM CONFIGURATION*Start From:--------------FRONTStart Type:--------------2 BUTTONControl From:------------FRONT%Tune Volts:-------------6%Display % Power:---------DISABLEDLock Front Panel---------DISABLEDDisplay Style:-----------BLACK TEXTAdjust Contrast:---------650Language:----------------ENGLISHRS485 Baudrate:----------19200RS485 Address:-----------32Temperature Mode:--------FahrenheitInterlock Reset From-----FRONTAutoreset Faults:--------DisabledThrough Heating:---------Disabled
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The selections for each characteristic are (default or factory setting underlined):
Start FromFRONT:to START heating from the front panelREAR: you attach your remote signaling source (PLC, relays, etc.) to TB1 at the rear (see 3) and
START with those signals.RS485: if Control From = RS485, below, select this to start heating with serial command (STOP
always works from front or rear)
Start Type2button: HeatOn when START is pulsed (or TB1 signal is closed) and remains on when released.
HeatOn ceases when STOP is pressed or when timer expires
1button: HeatOn only while button is pressed (or TB1 signal closed), ceases when button isreleased, when TB1 signal opens, when STOP is pressed or when timer expires.
Control FromFRONT: during HeatOn, RF output follows setpoint entered at front panelREAR 0-10V: your analog voltage signal controls outputREAR 4-20MA: your analog current signal controls outputProfile A - J...: use one of ten 10-step profiles you specify (2.5)RS485:adjust output with (optional) serial equipment, commands
% Tune Volts6: Standard setting. Adjust down to 2: to decrease the minimum operating voltage level. Adjust up
to 12: to increase the minimum operating voltage level.
Display % PowerDisabled: display units WEnabled:display figures as % full-scaleNote: Non-functional when the Control Method is set to kW.
Lock Front PanelDisabled: all touch pad buttons are enabledEnabled:These functions can be locked independently or collectively:TimerSetpointSystem Configuration Soft-keyWorkhead Config soft-keyEnter code 39889 to enable/disable Select and Adjust buttons;
START / STOP buttons are always enabled
Display StyleBLACK TEXTWHITE TEXT; sometimes called reverse video
Adjust ContrastTo change the contrast of the displayed characters Use / to adjust (lower number = lighter characters)
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LanguageEnglish: English | Spanish | French | German | Italian use / to select required language from memory
RS485 Baudrate38400: use / to select required baud rate
RS485 Address1: select from 1 - 32
Temperature ModeFahrenheit: select temperature units for display on the displayCelsius
Interlock Reset FromThis feature tells the system where to get the RESET signal, either from theFRONT: front panel soft key orREAR a 24V pulse (minimum 250ms) at TB1:2221 is required to reset the system.Equipment will never beginHeatOn immediately after a RESET. You must provide the STARTcommand
Autoreset FaultsDisabled: After a trip of certain fault codes (Power Module, Coil Short), the system must be RESET.System must be RESET following sensing and correction of FaultTime: set the delay interval between sensed Fault and Ready restoration
Through-heatingEnabled: especially useful for heating magnetic steel through Curie (2.10)Disabled: for rapid heating of well-controlled loads for under 5 seconds
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AMBRELL
The second configuration page presents these characteristics.
select BACK to return to the previous configuration page. select OPT CFG (Options Configuration). Details are addressed on the following
pages. select NEXT PAGE for additional configurationsAnalog Out Ch. 1, Ch.2
Control your auxiliary equipment or monitor EKOHEAT with this signal (3.1) representing:
OFF: no analog output%VOLTS: represents displayed output %Volts Note: Non-functional when the Control Method is setto kW.
%POWER: represents displayed output %Power%FREQUENCY: represents displayed operating frequencyNote: see Analog Output Scaling table (4.2)
Analog Out Mode Ch. 1, Ch.20-10V: signal presented at CTB2 spans this voltage range4-20mA: signal presented at CTB2 spans this current range
System Idle FrequencyIf you experience FREQUENCY BAND ERROR messages (2.8), and if you are confident your workheadconfiguration presents resonance within equipment range, you can adjust the starting or idlefrequency.*kHz: 4.2 PerformanceOtherGenerally, adjusting this figure away from the fault (for over-frequency fault, adjust idle frequency lower)will correct the error.
Power CaptureIf your heat cycle is between 100ms and 250ms, you may adjust this figure to better capture anddisplay the operating parameters during the first cycle.250ms:Other: set a briefer sample-rate with this field!!Do not adjust below 100ms!!
Display Max VoltsENABLED: display Vmax on main screenDISABLED: suppress Vmax on main screen
Advanced WHD CFGENABLED: permits special workhead limits (as directed by Ambrell Service only, please)DISABLED:
BACK
SYSTEM CONFIGURATION 2*Analog Out Ch.1-------OFFAnalog Out Ch.1 Mode--0-10VAnalog Out Ch.2-------OFFAnalog Out Ch.2 Mode--0-10VSystem Idle Frequency-10kHzPower Capture---------200msDisplay Max Volts---ENABLEDAdvanced WHD CFG----DISABLEDFast Boot-----------DISABLEDAlarm---------------DISABLEDAlarm Type----------DISABLEDAlarm Low-----------0.0 kWAlarm High----------48.1 kW
Alarm Delay----------200ms
OPTCFG
NEXTPAGE
Note: figures displayed on your system may vary from those shown here