PRECISION INDUCTION HEATING EQUIPMENT

OPERATION AND MAINTENANCE INSTRUCTIONS

30 & 45 kW Induction Heating Systems 100kHz ES Models

File Name Part Number Revision ECN# By Approved

801-9335-00.doc 801-9335-00 Rev N 1209-10 Dan King

Date

9/10/2012

This N revision has been written to: Delete OEM-specific references

Ambrell Companies
Ambrell www.ambrell.com +1.585.889.9000 Ambrell Ltd. www.ambrell.com +44 (0)1242 514042 Ambrell Sarl fr.ambrell.com +33 (0)3 89 76 01 24 Ambrell B.V. nl.ambrell.com +31 (0)548 659044

801-9335-00.doc Rev N | 2012 All information subject to change without notice

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Table of Contents
1 Introduction ........................................................................................................................... 5 1.1 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 How your EKOHEAT Works ............................................................................................ 19 2.1 Display, Control ............................................................................................................ 19 2.2 Detailed EKOHEAT Operation..................................................................................... 25 2.3 Navigation ..................................................................................................................... 27 2.4 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 Customizing Your EKOHEAT .......................................................................................... 41 3.1 Rear Panel Connections................................................................................................. 41 3.2 Optional Pendant ........................................................................................................... 47 3.3 Serial Control................................................................................................................. 49 3.4 RF Tap Adjustment ....................................................................................................... 59 Technical Information......................................................................................................... 63 4.1 Mechanical .................................................................................................................... 63 4.2 Electrical........................................................................................................................ 63 4.3 Environmental ............................................................................................................... 65 4.4 Contact Information....................................................................................................... 66

Introduction

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Notes:

In this manual, these symbols indicate:

a step in a procedure lighted indicators on the equipment A notice that requires your special attention; may pertain to safe operation of the equipment

manual sections

A notice that requires your special attention due to potential hazards to personnel or property

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1 Introduction
Your EKOHEAT is a solid-state induction heating system that converts 3-phase line voltage 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 features
Your EKOHEAT simplifies 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

Unpacking
Your 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 coil If 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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1.1 Safety Considerations

Your 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.
Electrical installations must be made by a qualified electrician and must conform to applicable safety codes.

Physical Risks
During the HeatOn cycle, high RF voltages are present at your work-coil. There are several risks, which we instruct you to protect against:
High Temperatures: take steps to prevent personal contact with the workpiece you are heating. Severe burns can result from contact at these temperatures! RF Voltages: we recommend that you provide protection against personal contact with the work-coil when it is energized (HeatOn). Induction burns: the energized work-coil causes nearby metals to become heated; DO NOT APPROACH ENERGIZED WORK-COIL WHILE WEARING OR CARRYING METAL OBJECTS! Pacemakers: high magnetic fields may be present. Pacemakers or other similar implanted devices may be adversely affected and the result could be dangerous or fatal.

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 the accepting hardware for your sheild scheme.

Safety Circuit
The EKOHEAT safety circuit includes: TB1 (provisional) interlock switch from the workhead (TB2:87 Interlock) 7 8 9 10 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 reclosed (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.
E- STOP IN E- STOP OUT

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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.
When this safety circuit trips, a contactor inside the equipment removes line voltage from the power conversion portion of the equipment, halting RF power output, but the disconnector switch, fuses, EMI filter and line-side of the contactor remain live and hazardous until the customer-supplied disconnect has been opened by you. Never operate this equipment with the covers removed!

1.2 Front Panel

Status Display Soft Buttons Navigation START STOP

Touch-pad & Display

Note: figures displayed on your system may vary from those shown here 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

Introduction

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1.3 Service Panel

Mains access

I/O access

Mains cable port

RF cable ports

Transformer cover PE Ground Cooling water ports

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.

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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 cover

Behind 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-relief bushing. 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 semiconductor fuses (4.2) here for their rapid-action. The protective earth ground (PE) connection is made at the indicated terminal. terminal on An additional protective earth (PE) ground connection is made at the 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 RF cable(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 cover
This 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 ports

Your EKOHEAT uses circulating water to cool internal components; inlet and outlet connections for the power supply are made at these rear panel ports. Internal flowswitches 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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1.4 Installing Your System

You may elect to use Ambrells Service Department to install your EKOHEAT equipment. 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 +1.585.889.9000 fax +1.585.889.4030 UK +44 (0)1242 514042 Europe/Middle East +31 548 659 044

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 or other mechanical assist. Do not lift equipment by side handles

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Access to the Power Supply

Electrical installations must be made by a qualified electrician and must conform to applicable safety codes. Your EKOHEAT system uses and produces high voltages! Routine configuration 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 AC Power Switch is off. Always turn off the customer-supplied fused disconnect before attempting any service. Caution: Stored electrical charge can persist at internal terminals for several seconds following disconnection of AC power! Allow 60 seconds after disconnection before touching or servicing internal components. The equipment requires two connections to protective earth ground. Failure to connect both protective earth grounds can result in a potentially hazardous condition if a single-point failure to earth ground accidentally occurs. Do not omit this step!

Power Supply and Cabling

(Refer to your Schematic Drawings) Your EKOHEAT system accepts 3 line-voltages from 360 to 520 Vrms. The mains fuse selection anticipates this supply voltage. See 4.2 for replacement mains fuse information. Plan a 5-wire routing for three phases and two protective earth grounds.

Disconnect
We 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

Conduit
We 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)

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Use a Philips screwdriver to loosen the 3 screws that 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 the mains 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 the wires of your cable (3 phases,& 2 GNDs) Apply ring lug to one of the ground wires and secure it to the post provided (PE). L1 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 next step. Apply a ring-lug to the second protective earth ground wire and secure it to the second post provided (PE)

L2

L3

PE

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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. These sense wires carry signals that enable your EKOHEAT to adjust its output to conditions at the workhead. Attach and secure the conduit and bushings between the work head and X2 power supply as required for your installation Route the RF cables through the conduit from the work head to the RF ports at the rear of the power supply Remove the transformer cover at the rear X1 of the equipment Remove the right-side cover (16 philips screws) 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 Sense Drain application; do not change without factory guidance) Attach and secure drain wire connections from RF cable(s) to Power stud, shown. Replace the transformer cover; record Tap# (3.4) Replace the right-side cover See 3.4 for Tap instructions

The RF power cable is constructed to specific requirements; it is a specialized cable. Do not substitute any other cable in its place. Failure to observe this caution can result in severely diminished performance and in cable over-heating. Call Ameritherm to replace or re-specify the RF power cable.

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1.5 System Cooling Requirements

Your 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.
Install a pressure regulator and a particulate matter filter (both non-ferrous) in the supply of your cooling water. Use copper, rubber hose, stainless steel or PVC tubing. Do not use ferrous pipe for this 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 Ethylene Glycol 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 cause catastrophic failure of your equipment. The maximum glycol concentration should not exceed 20% as cooling capacity is limited to 82% capacity (see chart). Concentrations greater than this can catastrophically impair the cooling of your power supply, workhead and coil.

Power supply cooling water

Power 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/m@2.8 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)

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Work head cooling water

Each 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 of 40psi (2.8 bar) differential pressure across the system. See 4 for important cooling water minimum flow figures Install a shut-off valve upstream and convenient 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 be monitored, 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)
TB2 FLS 3[140] FLS4[142] GND[141,143] INTLK [146] INTLK [147] + 7 8

+ 5

4 Route the capacitor flow-switch wires [FLS3 140:141] to WORKHEAD TB2:64 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.

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1.6 Safety Means and Connections

Your work head 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 risks
During HeatOn, high AC voltages are present at your work-coil. There are several risks, which we instruct you to protect against:
High Temperatures: take steps to prevent personal contact with the workpiece you are heating. Severe burns can result from contact at elevated temperatures! High RF Voltages: we recommend that you provide protection against personal contact with the work-coil when it is energized. Induction burns: the energized work-coil causes nearby metals to become heated; DO NOT APPROACH ENERGIZED WORK-COIL WHILE WEARING OR CARRYING METAL OBJECTS!

Interlocked barrier
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 the accepting hardware for your sheild scheme. Use a normally-open switch which closes only when the barrier is fully closed. A Faraday cage can double as a mechanical barrier!
TB1 5 6 7 8 9 10 11 12 + - + - + - + -

E- STOP IN

E- STOP OUT

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.

Introduction

AN:IN1

READY

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Faraday cage

If, during HeatOn, you experience unacceptable interference with surrounding equipment (AM radios, Hall-effect switches, etc.) you can reduce this interference by constructing 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; these are insulators and they defeat the cages purpose.

Safety Circuit
The EKOHEAT safety circuit includes: (provisional) interlock switch from the workhead (TB2:87 Interlock) your (optional) N.C. E-STOP switch (TB1:87) Your switch can be installed at the terminal block (TB1:87; factoryjumpered); when your switch opens, all output power ceases. After the safety issue has been resolved and the switch has been reclosed (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.
TB1 7 8 9 10 + - + -

E- STOP IN

If your EKOHEAT was purchased (optional) with an E-STOP switch installed on the front panel, E-STOP OUT will be configured to re-transmit the state of the E-STOP IN port for use in your larger system.
When this safety circuit trips, a contactor inside the equipment removes line voltage from the power conversion portion of the equipment, halting RF power output, but the fuses, disconnect switch, EMI filter and line-side of the contactor remain live and hazardous until the customer-supplied disconnect has been opened by you. Never operate this equipment with the covers removed !

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2 How your EKOHEAT Works

When 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)

2.1 Display, Control

The EKOHEAT concentrates control and status information within this panel:
Ready HeatOn Limiting Fault Select Adjust

Displayed data OUTPUT: (V or kW when heating) SETPOINT: required output level TIMER: count-up, count-down or continuous FREQUENCY: of output

START

STOP

Soft Buttons

Home

START/STOP to initiate heating from front panel

Soft Buttons to select specific features

Note: figures displayed on your system may vary from those shown here

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Simplest example

In this example, you heat the part at 200V Setpoint. Note: figures displayed on your system may vary from those shown here

0V 200V 0ms 121kHz

1

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

Do this...
open water-valve for the system check the work-coil check condition of (any) safety barriers or limit switches turn on EKOHEAT

Observe...
check drain; ensure water is flowing ensure there is no work-piece yet all safety devices are clear, electrically closed Ready LED (is ON)

Use Select buttons to highlight SETPOINT or TIMER and to scroll through onscreen 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 part not contacting coil; do not hold

secure unheated part in coil

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201V 200V 0ms 121kHz

3

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

Press START to begin induction heating. Press STOP to halt induction heating

press START
press STOP remove heated part from coil

HeatOn, Ready Ready only avoid contact with heated portions

Timed heating
In this example, you heat the part at 200V output for 10 seconds. EKOHEAT halts heating when the Timer duration you set has expired. Do this...
use Select buttons, highlight Timer press Home button use Adjust buttons until: secure unheated part in coil press START remove heated part from coil

Observe...
Os note T subscript on display 10s part not contacting coil; do not hold HeatOn, Ready Ready only, after timer expires avoid contact with heated portions

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Display features

568V 568V 0ms 121kHz

OUTPUT

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

Note: figures displayed on your system may vary from those shown here

Actual voltage at the output when HeatOn. Larger values result in faster heating or hotter parts. 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

568V 568V 0ms 121kHz

SETPOINT

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

This is your desired output setting. Use to locate the pointer at SETPOINT, then increase or decrease the output setting with the / buttons. EKOHEAT works to match the RF output to this setting when the RF power is on (HeatOn).

568V 568V 0ms 121kHz

FREQUENCY

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

This is the RF output frequency when HeatOn. It is the resonant operating frequency and is the 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 last resonant frequency. Sometimes, you may see that the output frequency approaches either end of the operation range of EKOHEAT (4.2) and the display advises you to increase or decrease capacitance. Please call Ambrell for assistance should this happen and we will supply you with the appropriate capacitors.

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568V 568V 0ms T 121kHz

TIMER

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

Note T , timer or C , count up displayed near arrow; Press to toggle the cycle-time display 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 values between 10 milliseconds and 9999 seconds with the / buttons; press START: heating continues for the duration of your setting or until STOP signal is received. 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 next START signal or until TIMER function is selected

568V 568V 0ms 121kHz

Load Matching

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

While heating, EKOHEAT reveals how power is being transferred to your part. Your loading is evaluated to determine matching (%MATCH) for the RF tap selection in use. 100% MATCH is 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 in output limiting 2.2

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568V 568V 0ms 121kHz

SYS CFG
PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

WHD CFG SYS STAT

Power & Temperature

In the lower center of the display, the output is shown in alternate units (kW if Volts used on main display, vice versa). The temperature of the enclosure air and heat sink are displayed below that. EKOHEAT cutsback output power if these temperatures exceed a factory-set maximum.

568V 568V 0ms 121kHz

Messages

MESSAGES: Displayed when fault conditions are tripped PWR 0kW %MATCH VMAX = 977V TEMPERATURE Air 77F Hsnk 73F

SYS CFG WHD CFG SYS STAT

In the upper center of the display, EKOHEAT reveals any corrective messages pertaining to its operation or status: Flow switch trips; inadequate water flow safety switch trips; see 2.8 for full list of Messages and recommended corrective actions

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2.2 Detailed EKOHEAT Operation

This section details how to: interpret the Status LEDs use touch panel features understand system Faults and Advisories

Status LEDs Ready

EKOHEAT is waiting to heat; no faults detected

HeatOn
START command received, outputting power per settings. It may be possible to achieve a more efficient configuration, though output is within acceptable margins.

Limiting

Either the Voltage, Power or Temperature values have reached their maximum limits. See 2.8 for further information.

Fault

Heating interrupted; fault detected; correction required. Read display for information about the Fault

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Touch-panel features
Select

Use Select buttons to highlight SETPOINT or TIMER and to scroll through onscreen lists

Adjust Use these buttons to adjust on-screen figures such as SETPOINT, TIMER, etc.

Home

Use this button to take you back to the Home screen. With the Home screen displayed, highlight SETPOINT; then press this to display workhead VOLTS or kW TIMER; then press this to display Timer (T) or Counter (C)

START

When starting the unit from the front panel, use these buttons to (de)activate heating. Press START to begin induction heating. HeatOn (LED) shines and the display is updated with operating data. START operates only when HOME screen is displayed

STOP

Press STOP to halt induction heating (2-button start type). The unit returns to Ready state. (STOP signal from front or rear panel always halts induction heating)

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2.3 Navigation
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 your EKOHEAT operates WHD CFG, (Work head Configuration); use this interface to inform the EKOHEAT about the configuration of the attached work head and RF tap settings. 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

2.4 System Configuration

Several operating characteristics of the EKOHEAT can be changed to suit your process needs.
SYSTEM CONFIGURATION *Start From:--------------FRONT Start Type:--------------2 BUTTON Control From:------------FRONT %Tune Volts:-------------6% Display % Power:---------DISABLED Lock Front Panel---------DISABLED Display Style:-----------BLACK TEXT Adjust Contrast:---------650 Language:----------------ENGLISH RS485 Baudrate:----------19200 RS485 Address:-----------32 Temperature Mode:--------Fahrenheit Interlock Reset From-----FRONT Autoreset Faults:--------Disabled Through Heating:---------Disabled

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FILES

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. use Adjust / 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

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Start From
START with those signals.

The selections for each characteristic are (default or factory setting underlined): FRONT:to START heating from the front panel REAR: you attach your remote signaling source (PLC, relays, etc.) to TB1 at the rear (see 3) and RS485: if Control From = RS485, below, select this to start heating with serial command (STOP
always works from front or rear)

Start Type
2button: 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 is released, when TB1 signal opens, when STOP is pressed or when timer expires.

Control From
FRONT: during HeatOn, RF output follows setpoint entered at front panel REAR 0-10V: your analog voltage signal controls output REAR 4-20MA: your analog current signal controls output Profile A - J...: use one of ten 10-step profiles you specify (2.5) RS485: adjust output with (optional) serial equipment, commands

% Tune Volts
6:
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 % Power
Disabled: display units W Enabled: display figures as % full-scale
Note: Non-functional when the Control Method is set to kW.

Lock Front Panel

Disabled: all touch pad buttons are enabled Enabled: These functions can be locked independently or collectively:
Timer Setpoint System Configuration Soft-key Workhead Config soft-key Enter code 39889 to enable/disable Select and Adjust buttons; START / STOP buttons are always enabled

Display Style
BLACK TEXT WHITE TEXT; sometimes called reverse video

Adjust Contrast
To change the contrast of the displayed characters Use / to adjust (lower number = lighter characters)

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Language
English: English | Spanish | French | German | Italian
use / to select required language from memory

RS485 Baudrate
38400: use / to select required baud rate

RS485 Address
1: select from 1 - 32

Temperature Mode
Fahrenheit: select temperature units for display on the display Celsius

Interlock Reset From

This feature tells the system where to get the RESET signal, either from the FRONT: front panel soft key or REAR a 24V pulse (minimum 250ms) at TB1:2221 is required to reset the system. Equipment will never begin HeatOn immediately after a RESET. You must provide the START command

Autoreset Faults
Disabled: 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 Fault Time: set the delay interval between sensed Fault and Ready restoration

Through-heating
Enabled: 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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SYSTEM CONFIGURATION 2 *Analog Out Ch.1-------OFF Analog Out Ch.1 Mode--0-10V Analog Out Ch.2-------OFF Analog Out Ch.2 Mode--0-10V System Idle Frequency-10kHz Power Capture---------200ms Display Max Volts---ENABLED Advanced WHD CFG----DISABLED Fast Boot-----------DISABLED Alarm---------------DISABLED Alarm Type----------DISABLED Alarm Low-----------0.0 kW Alarm High----------48.1 kW Alarm Delay----------200ms

BACK NEXT PAGE OPT CFG

Note: figures displayed on your system may vary from those shown here 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 configurations

Analog 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 set to kW. %POWER: represents displayed output %Power %FREQUENCY: represents displayed operating frequency Note: see Analog Output Scaling table (4.2)

Analog Out Mode Ch. 1, Ch.2

0-10V: signal presented at CTB2 spans this voltage range 4-20mA: signal presented at CTB2 spans this current range

System Idle Frequency

If you experience FREQUENCY BAND ERROR messages (2.8), and if you are confident your workhead configuration presents resonance within equipment range, you can adjust the starting or idle frequency. *kHz: 4.2 Performance Other Generally, adjusting this figure away from the fault (for over-frequency fault, adjust idle frequency lower) will correct the error.

Power Capture
If your heat cycle is between 100ms and 250ms, you may adjust this figure to better capture and display the operating parameters during the first cycle. 250ms: Other: set a briefer sample-rate with this field !!Do not adjust below 100ms!!

Display Max Volts

ENABLED: display Vmax on main screen DISABLED: suppress Vmax on main screen

Advanced WHD CFG

ENABLED: permits special workhead limits (as directed by Ambrell Service only, please) DISABLED:

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