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EFD MINAC 25 Twin User Manual

Mobile induction heating equipment
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Mobile Induction Heating Equipment
Manufacturer:
EFD Induction a.s
P.O. Box 363, N-3701 Skien, Norway
Tel: +47 35506000
© No part of this publication may be reproduced in any form without the
express written permission of EFD Induction a.s. EFD Induction a.s
reserves the right to change technical specifications without notice.
MINAC Systems
USER MANUAL
MINAC 25/40, 50/80
MINAC 25 Twin
Version MCCC 2.2.1
Fax: +47 35506010

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Summary of Contents for EFD MINAC 25 Twin

  • Page 1 P.O. Box 363, N-3701 Skien, Norway Tel: +47 35506000 Fax: +47 35506010 © No part of this publication may be reproduced in any form without the express written permission of EFD Induction a.s. EFD Induction a.s reserves the right to change technical specifications without notice.

  • Page 2: Table Of Contents

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc C O N T E N T S INTRODUCTION ....................1 SAFETY INSTRUCTIONS, PRECAUTIONS AND HAZARDS......2 General......................2 Electric Shocks ..................... 3 Heated Objects..................... 3 Electromagnetic Fields ................. 4 RESTRICTIONS IN USE ..................
  • Page 3 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 6.2.4 Alarms during start-up ................28 Normal Operation ..................28 6.3.1 Operational Information ................29 6.3.2 Control Functions ................... 29 6.3.3 Output Power ..................31 6.3.4 Distance to Workpiece................31 Normal Stop....................

  • Page 4: Introduction

    INTRODUCTION This manual provides step-by-step operation instructions for the MINAC standard 25/40 and 50/80 systems and MINAC 25 Twin systems. It also contains safety information and instructions, and some simple corrective measures. The operation instructions must be read thoroughly before the equipment is used.

  • Page 5: Safety Instructions, Precautions And Hazards

    All personnel operating, maintaining or working in close proximity to the equipment MUST thoroughly read, understand and obey the safety instructions that apply to this equipment given by EFD Induction a.s. Only properly trained personnel who are familiar with the technical handbook should be permitted to open the covers for servicing this equipment.

  • Page 6: Electric Shocks

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Electric Shocks WARNING! Electrical shocks can result in personal injury or loss of life. To avoid the risk of an electric shock, DO NOT: • open the equipment covers during operation •...

  • Page 7: Electromagnetic Fields

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Electromagnetic Fields WARNING! Electromagnetic fields can be a health risk. All induction heating equipment produces electromagnetic fields that are concentrated inside the coils. The field’s strength depends on the current’s strength and the number of turns in the coil.

  • Page 8: Restrictions In Use

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc RESTRICTIONS IN USE Only use the MINAC solely for its intended purposes under safe conditions and in proper surroundings. Take great care when using the equipment. Heat only electrical conductive materials. The presence of combustible materials involves a risk of fire. The MINAC systems provide the following output power limitations for continuous use and intermittent duty: Equipment...

  • Page 9: Connecting And Using The Coil

    If contact is difficult to avoid, coat the coil with an aluminum oxide (avoid oxide on the contact surface). This will reduce the risk of short circuits. Coils supplied by EFD Induction a.s are already coated with an aluminum oxide.

  • Page 10: Man-Machine Interface

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc MAN-MACHINE INTERFACE Display and Keyboard The display and keyboard together form the frequency converter's Man-Machine Interface (MMI) and are located on the operating panel. A number of different menus are available to the operator. The starting point for access to these menus is the Main Menu (menu 1), which gives an overview of the menus available.
  • Page 11 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Figure 5. Display and Keyboard. Table 1. Keyboard Keys and Functions Function Ten function keys, F0-F9 For selecting different functions. F9: For returning to the previous menu. Number keys, 0-9 For typing numbers.
  • Page 12 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Figure 6. Switches and Indicators Table 2. Switches and Indicators, and Functions Type Function AUX Voltage indicator Indicates that the voltage for the auxiliary circuits is on. Ready indicator Indicates that the MINAC system is ready for use. Failure indicator Indicates that some fault condition is present.

  • Page 13: Footer Messages

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 5.1.1 Footer Messages Each screen shown on the display contains a footer field where the following information is displayed (with priority as indicated): 1. Alarm messages. 2. Indications/limitations when the power is on. 3.
  • Page 14 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Indications/Limitations during Power On The purpose of these limitations is to achieve an optimal combination of maximum output power and sufficient overload protection of the equipment. • Low frequency current limit The voltage across the transformer has reached a preset maximum level for the current load and frequency level, preventing further increases in output power.

  • Page 15: Menus

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc • Extended Operating Range Activated The Extended operating range function has been activated, enabling the unit to operate outside the normal ratings for cooling water flow and temperature. This message flashes, alternating with the rest of the ‘Messages during normal operation’.

  • Page 16: Pin Code Menu (Menu 26)

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Timer <ACTIVE/OFF> Water auto shut-off <ACTIVE/OFF> Energy supervision <ACTIVE/OFF> PIN code <ACTIVE/OFF> Language Change to next available language Extended Operating Range <ACTIVE/OFF> Select Ext.interface <Hardwired/Fieldbus1> Return to the Main Menu by pressing F9. 5.2.2 PIN Code Menu (menu 26) This menu provides a security option for the system through the entry of a Personal...

  • Page 17: Change Pin Code Menu (Menu 27)

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 5.2.3 Change PIN code Menu (menu 27) This menu allows the operator to change the PIN code. First enter the old PIN code and then enter the new PIN code twice: Give old PIN code: <0-9999>...

  • Page 18: Timer Menu (Menu 7)

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 5.2.5 Timer Menu (menu 7) This menu enables the operator to program the timer. Time Unit <0.1 s/1 s/0.1 m/1 m/0.1 h> Time <0-999> Select the time unit by pressing the F0 key. Use the down arrow key ⇓ to go to the "Time"...
  • Page 19 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Table for Registering Program Settings Mode of Operation: AC current / DC power / Temperature Program No: Segment no. Segment type Segment duration Target setpoint © For reproduction rights, see cover page. Page 16...
  • Page 20 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Example of a Sequence Figure 7 illustrates a heating sequence, while Table 1 shows the sequence parameters. The example on the next page shows how to program this sequence. Setpoint [%] Segment no 0 Segment no 1 Segment no 2...
  • Page 21 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Programming example 1. SELECT SEQUENCE MENU Press F3 when in the Main Menu. 2. SELECT PROGRAM NUMBER Press F0 until the number 2 is displayed. 3. SELECT SEGMENT NO 0 Press F1 and the number 0 is displayed.
  • Page 22 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 14. SELECT SEGMENT TYPE Press F2 if "STEP" is not already set as the segment type. 15. SELECT TIME UNIT Press F3 until "1 m" is displayed. 16. ENTER NUMBER OF TIME UNITS Enter the number 4.

  • Page 23: Energy Menu (Menu 8)

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 5.2.7 Energy Menu (menu 8) This menu enables the operator to see how much energy was used in the last sequence, both overall and for each segment. It is possible to store the total energy value (one value per program) and state an allowed energy deviation value (as a percentage) for comparison against later sequences.

  • Page 24: Event Output Menu (Menu 30)

    In some cases when using temperature mode of operation, it is preferred to disable energy count below a certain temperature to minimize the influence on the total energy caused by variance in the work piece start temperature. This function has to be configured by EFD personnel. 5.2.8 Event output menu (menu 30) In this menu a specific event can be configured to trigger an output during a sequence program run.

  • Page 25: Display Values (Menu 24)

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 5.2.9 Display Values (menu 24) This menu provides information on normal operational values. It displays a continuous graphical presentation of AC current and DC power. The programmed setpoint is marked on the bar graph representing the selected mode of operation. The AC current frequency is indicated on the right upper side of the AC current bar graph.

  • Page 26: Operation

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc OPERATION WARNING! avoid personal injury, open equipment's covers or panels. Under any circum- stances, do not operate the equipment without the covers and panels properly installed. Before Starting 1. Place the induction heating unit in its working position. 2.
  • Page 27 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 3. According to IEC 60204-1, paragraph 5.3.2, the plug on the main supply cable is known as the “supply disconnecting device.” To comply with this regulation the unit must be connected to the main power supply by means of this plug-socket combination.

  • Page 28: Start

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Start 6.2.1 Main switch Main switch Figure 11. MINAC 25/40 and 50/80 cabinet front, main switch 1. See figure 11. At the front bottom of the cabinet, turn on the converter's main switch.

  • Page 29: Power On

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc • Sequence • Timer • Water Auto Shut-off • Energy Supervision • PIN Code • Language • Extended Operating Range The sequence and timer functions are mutually exclusive. For further information about the control functions, refer to paragraphs 5.2.1 and 6.3.2.
  • Page 30 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc POWER LOCAL/ REMOTE selector POWER Figure 12. Switches and Indicators panel, POWER ON/OFF buttons 2. Local Control from Operating Panel The LOCAL/REMOTE selector must be set to LOCAL when the MINAC is operated from the operating panel only.

  • Page 31: Alarms During Start-Up

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc timer/sequence can be started. Setpoint source: LOC, EXT, HHT or DEFAULT. 4. External Control Different types of ECUs can be used to operate the frequency converter. The start-up sequence will vary depending on the type of ECU used. Make sure that the LOCAL/REMOTE selector is in the REMOTE position.

  • Page 32: Operational Information

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 6.3.1 Operational Information During normal operation, select one of the MMI information screens: • Display Values (menu 24) • Display All Values (menu 19) • Display Timer/Sequence (menu 23) • Display Twin Values (menu 36) (Twin units only) Refer to paragraphs 5.2.9, 5.2.10, 5.2.11 and 5.2.12.
  • Page 33 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Energy Supervision The energy supervision function enables the operator to detect changes in the heating process when running the sequence function. Once a perfect sequence program has been established, store the total energy value of the run and enter an allowed percentage energy deviation value.

  • Page 34: Output Power

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc 6.3.3 Output Power There are the following maximum output powers available for continuous use and intermittent duty: Equipment Continuous use Intermittent duty MINAC 25/40, 25/40 Twin MINAC 50/80 The maximum output powers are attainable only with low Q - magnetic steel. The output power can be regulated by using the following three different parameters (modes of operation): AC current...

  • Page 35: Normal Stop

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Normal Stop 1. Turn the output power off by pressing the POWER OFF button on the operating panel or an equivalent actuator on the ECU, or by releasing the button on the HHT handle.

  • Page 36: Restart After Emergency Stop Command

    MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Restart after Emergency Stop Command. RESET Figure 13. Switches and Indicators panel, RESET button To restart after an Emergency Stop caused by an ECU, release the emergency stop from the ECU and press the “RESET” button on the operating panel. The unit will be ready to receive a new power-on command.

  • Page 37: Disturbance Of Operation And Corrective Measures

    EFD personnel or qualified on-site maintenance personnel normally should take corrective actions. However, the operator may handle the alarm situations set out below. If these actions do not restore normal operation, the operator must record the error message and contact the on-site maintenance personnel, EFD Service Department or the nearest EFD representative.
  • Page 38 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Operational Failures Alarm Probable Cause Corrective Action Switch mode power – A missing phase. 1. Make sure that the supply voltage supply alarm consists of all three phases. – Main fuse break. 2.
  • Page 39 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Alarm Probable Cause Corrective Action Over-current Possibly caused by a short 1. Check for short circuits in the driver alarm in the output circuit, or a induction coil and its terminals. Make malfunctioning transistor.
  • Page 40 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Alarm Probable Cause Corrective Action Water flow low – Insufficient water flow 1. Check that external manual valves through the converter and solenoid valves are open. Indicates insufficient module heat sink. 2.
  • Page 41 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Alarm Probable Cause Corrective Action Power on by startup There was a “Power on Release any stuck power-on buttons, command” detected by the and press the RESET button to make control system during the unit ready for use.
  • Page 42 MINAC Systems Revision A USER MANUAL 31 January 2005 63860.doc Alarm Probable Cause Corrective Action Main contactor off Refer to the emergency stop alarm The main contactor is not energized because On twin units this alarm Emergency stop is will stop both outputs activated —...

This manual is also suitable for:

Minac 25/40Minac 50/80

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