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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

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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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Introduction 5

Precision Induction Heating

801-9335-00.doc

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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Introduction6

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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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Introduction 7


801-9335-00.doc

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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Introduction8

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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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Introduction 9


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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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Introduction 11


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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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Introduction12

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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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Introduction 13


801-9335-00.doc

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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Introduction14

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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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Introduction 15


801-9335-00.doc

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


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AMBRELL

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


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801-9335-00.doc

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



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



SYSCFG

WHDCFG

SYSSTAT

568V

568V

0ms

121kHz



SYSCFG

WHDCFG

SYSSTAT

568V

568V

0ms

121kHz



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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801-9335-00.doc

568V

568V0ms

121kHz



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



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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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



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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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:


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


Documents

EK 30-45 kW OM -00.1-30