User Manual for Induction Heater INCOIL model IH series
Contents
1. Handling Care and Maintenance The unit contains sensitive electronic components and is not shock resistant never drop the unit Do not use the unit when there is damage to the enclosure power cord and transformer with water cooled cables or coil There is dangerous voltage inside the unit never open the unit Do not insert objects into it Make sure the power cord hose package and coolant hoses are not squashed In case of damage to the unit contact your dealer Do not place any object on the unit that contains water or other liquid and do not expose the unit to moisture Do not use the unit in moist or dusty areas and don t expose it to extreme heat maximum 35 degrees Do not cover the unit with subjects or others that might prevent cooling Allow space at the back sides and under the unit Do not use deformed or repaired coils which can cause a short circuit or low water flow If the unit is exposed to the cold condensation can form let it therefore remain unconnected indoors for an hour before it is used or connected During electrical storms plugged in units can be damaged therefore always pull the power cord Never use the unit outdoors in wet weather When the unit is not used for a long time the power plug is to be pulled out and the water turned off Metallic objects close to the coil can be heated Do not heat too close to electrical equipment it can be damaged by the magnetic field2. Frequency Resonant current Program select Mains current Progress Operation time Settings Panel Locked Max Power Program Select Max Temp Work Obj Temp sens WorkObj Max Resonan Curr Pyro Emissivity Time Cooling Water Time Sprak Language PLC Voltage Range Fan High Temp Alarm No Heat temperature and Time Temp Regulate P amp D Network Heating Programs Program Depending on the current configuration Temperatures IGBT Max IGBT Water in Rectifier Water out Work object Temperature Scale Diagnostic Mains current Mains voltage Mains voltage S Mains voltage T Phase Order Flow monitor Flow monitor Ext Heat switch Temp sensor work object IrTolmain lp address Navigating the Menu The display has four rows Please note the little triangle on the left hand of the display It is the marker and shows what option is selected To navigate between the main pages use Arrow Left amp Arrow Right The system always starts in Operation menu With one press on the Arrow Right Settings is displayed one more press and Heating Programs or Temperatures in machines without programs with more presses finally Product Information will be displayed and one more press will show the Operation menu again It is possible to navigate in reverse order with Arrow Left Heating Programs Operation gt Settings gt gt Bedsits Pro
3. Resonanscurrent high Heating stopped as possible Contact dealer Resonanscurrent low short circuit was detected Contact dealer Low mains voltage One or more phases missing Check phases and fuses or voltage too low Contact dealer No Current flow No current flows in the Check coil and its resonance circuit connections Contact dealer Temp sensor IGBT Unable to measure the Contact dealer temperature of internal Temp sensor w out temperature sensors Contact dealer Temp sens WorkObj Heater set to operate with Check pyrometer and external pyrometer but the cables heater cannot establish connetion Emergency stop Emergency stop was pressed Release when safe and acknowledge Contactor Contactor is in the wrong Contact dealer Internal position cable error Heating switch If button to start heating is Release switch and pressed when unit is in acknowledge Check standby cables if error persist No Water flow detected when Check waterflow No Water flow ext in On Water flow detected in Water valve may be Unexp W flow ext standby on machines with damaged or water flow internal water valve sensor damaged Contact dealer Temperature IGBT Temperature too high on Internal electronics have IGBT become very hot should not occur unless some error Contact dealer Water temp in Temperature too high on Check incoming water into the machine watersupply Difficult to cool with hot water Water temp out Tempe
4. Workobj Technical specifications IHS 1H10 1H18 IH25 Continuous Output power kVa 3 5 10 22 22 Supply voltage current range 230 16 400 16 400 32 400 32 Cooling Intern Extern Extern Extern 3 8 3 8 3 8 Water pressure bar min max Max temperature water 40 C 40 C 40 C 40 C Chassis width 310mm 310mm 300mm 310mm Total weight approx 28kg 43kg 25kg 43kg Transformer length standard 3 m 1 2 3 3 5 7 10 3 5 7 10 IH30 IH50 IH80 Continuous Output power kVa 30 44 80 Frequency Range kHz Supply voltage current range 400 50 400 63 400 125 Power Frequency Hz 50 60 50 60 50 60 Cooling Extern Extern Extern Water consumption L min Water pressure bar min max 3 8 3 8 3 8 UI O O Max temperature electronic 50 C Max temperature water 40 C 40 C Chassis width 310mm 310mm 400mm Total weight approx 45kg 45kg 70kg Transformer length standard 3 m 3 5 7 10 3 5 7 10 3 5 7 10 Security Class Standard EN 61000 6 4 EN 61000 6 2 EN 60335 1 NS O O Warranty 1 year guarantee from date of sale Damage caused by carelessness during handling and transport is not covered by the guarantee The use of induction coils which are not made for the unit and therefore causing damage is not covered by guarantee Always contact the dealer manufacturer for the design of induction coils Damage caused by faulty electrical connection or cooling problems dirty cooling water is not covered under guarantee Squeeze injuries
5. check that its lens is clean Clean the coil from soot and dirt Cooler if installed o Check that the radiator is free of dirt and dust o Make sure that no debris or trash has fallen into it Check water filter if installed Monthly maintenance Check the water level in the cooler Check the water quality A cooler might have requirements to change the water on a regular basis The Heater has no trouble running with the same water as long as the water is clean Yearly maintenance All items are handled during more frequent maintenance Explanation of Symbols To get the best out of the unit read instructions and safety before use These symbols are placed on the unit s chassis This symbol indicates that there is dangerous voltage inside the unit This symbol will alert you that there are important instructions for the handling care and maintenance in the instructions that come with the product Pacemaker forbjuden This symbol indicates that people with pacemakers should not be staying close to magnetic fields This symbol indicates that you should not stand on or charge the unit s chassis with high weight Preparation Installation Installation of the coil The contact surfaces of the coil and transformer must be undamaged and clean O rings must be intact and of the right dimension 7x2 5mm standard transformer 6 1x1 6mm lightweight transformer The nuts on the bayonet coupling should be easy to th
6. of the hose assembly and transformer are not covered by warranty Induction coils are excluded from the guarantee Company details Incoil Induktion AB Brandthovdagatan 29 SE 721 35 V ster s Sweden Tel 0046 0 21 418385 Fax 0046 0 21 418384 Email incoil incoil se www incoil se Inco
7. Now changing the selected parameter or part of a parameter is done using Arrow Left to decrease the value and Arrow Right to increase the value If the arrow is pressed and held the change is accelerated Releasing the arrow will allow the change rate to start to decrease To complete the change of the parameter Button OK has to be pressed Only then will the parameter change its value If you navigate above the top value for a multi row parameter like time or press Arrow Up for a single line parameter like Max Power then the edit is cancelled Settings Panel Program Max Temp Locked Select Work Obj Change Change Change setting setting Change setting setting Note Network parameters that is last in the list of parameters has its own submenu and to access the parameters for this an additional Arrow Down has to be pressed before changing those parameters Other menus Temperatures and Diagnostics menus work in the same way as the Settings menu A list of parameters but only one displayed at a time Here no changes can be made except one In Temperatures menu it is possible to change from Celsius to Fahrenheit if that is preferred Alarms looks more like the Operation menu with a list of active alarms It is however rare that the list will be so long that all cannot be displayed Product Information is also like Operation menu with versions of SW and dates The Heating Programs menu is described in a separate docume
8. User Manual for Induction Heater INCOIL model IH series Carefully read the manual Original instructions Table of contents Mro dU Oare E E E E E 3 Handling During TUS OG Ecce cso nec sua tacedcaan aon ane O a EOE N O E 4 I Fen TSC OI VCCI einernie NE E EE NRA 4 Handling Care and IWial NEC MAN CC ars ceccauindosssenacasaeresancesesacasaudndersuenaseneresenensecvotessceandeanmeasdeesceaeacsat 5 SV I E sauce awe aisecuet enone net sows cage nacceas esasaoaciavsenee eaeseeananveegsbacuataes sasdnaueaeceaee ancuneeae 5 Vendla UO Sacer sets sates esha E E E ediabosteassnaunsaucedoeednceseoatcdiatesiascuues4y ssd sit 5 NC A E E cea ences E EE O E E E E T 5 OT OC ie OUR TIE OUT e EEE EOE A E SEE 6 Weekly MeN CC VAIN CO saagadics aansnedoncdedentccasatvotanabasedansvaboiedsdeabavasanaotansteddadavabeietsaestsvesateetatsteneseeds 6 IVFOTYER Ly TAAL OO UG a E E E AEE 6 XGA id UNO ANG A TE E E E E E E E ET N 6 EoLA SHOOT VINDO arne E ene en eee ee ee 7 Preparations INSTA MAT OT euas E ISIN NANNE NNE 8 NS FANA MOTTO TENS CO E A E E Sonne den E ROR E E EE T 8 Morala on STOD e O 8 Snein AEE E E E A E A E E A E E A 9 PUOC ON o E E E E E E E E E E E E E E E 10 FORtF l Panel fUIFVET Oaren eE ETUS 11 Menu structure of the control panel nnmessesssressrrrsrrrrsrrrerrrrrerrrrrerrrrrrrrrrr sees ers r nns r rr rs rer r ers r rens r sn 12 NIST OPERA CIO a terassopien E tsarens oder d 18 PY SS SS caret elect cts E srns d cee regs dere Na r de
9. ad and change settings in the system hence the name Settings can be Max Power Use pyrometer or not and others All are presented below in Menu Settings As in the Operation menu there is a list of options here but instead of displaying them on top to bottom only one parameter at a time is displayed The current value of the parameter is displayed on the row below the name To view the current list of settings first the settings menu have to be selected Then press Arrow Down to select the Parameter level Se picture below and note the little triangle k Max Power is selected here and the triangle is now pointing on the Max Power name To change a parameter e First select the parameter to be changed e Then press Arrow Down See picture below Note the gt twin arrows showing that we are now in change mode The triangle remains on the name The parameter may have more than one row to edit See below what happens when I choose to edit the time It has one row for year month day hour minutes and finally one for seconds The gt will indicate which row is currently being edited and the Arrows Up Down on the left hand screen indicate that there is more to be displayed above and below NOTE Pressing Arrow Up when editing the top value Year in time or when editing a single row value like Max Power will end the editing and no change to the parameter is done Reached the bottom for editing the Time parameter
10. as the value To Change the pin code This needs to be done from an unlocked system Hmm how odd Navigate to the Panel Locked setting and press the Down key Five rows of settings are now available Lock Unlock and the four digits in the pin code The first line must be left as Unlocked value Change the pin code digits as desired Press the OK key to store the new pin The system is still unlocked and Unlock should be displayed as the value Menu Temperatures IGBT Current temperature of IGBT Max IGBT Maximum temperature of IGBT ever reached Waterin Temperature on Water into heater dependent on configuration Temperature on rectifier dependent on configuration Temperature on Water out of heater Work object Temperature on work object if pyrometer present Not part of Limited Celsius Fahrenheit Set temperature to be displayed in Celsius default or Fahrenheit Menu Diagnostic Mains Voltage Measured Mains Voltage Mains Voltage R Mains Voltage S Additional two phases when present Mains Voltage T Phase Order Shows the Phase order of Input Mains RST or RTS If a cooler is supplied by Incoil and its power supply is connected thru the IH machine the phase order should be RST The cooler needs a correct phase order for the fan and pump to operate in the correct direction If a phase change connector is present on the cooler it should have a mark which will indicate the correct setting when the machine detects RST o
11. bereder E RNE 19 Pa Ne L T KET ee Aencsrabetetatne seine ia artens n e SN NN RN 21 Menu temperaturos 4smumpnmadssmbusksuniies sdonkds AEE EEEE EEDA BIN Sr Oe 22 Menu Da NO HO erens ean E E E E E E 23 Mont TAU INNS ean E E EE E E E eeaasaeeenaes 24 Message MITRE di play reniras anne E EE EEEE OEE aiaei 25 TECHINCELS PECO UI OM S rice oran a EN E E EEE 28 WY AN VU E E EA AE AEE A EA A E A E A EEA 29 COMPAN A EA AA E EE EE 30 Introduction This manual explains how the heater is controlled by the various buttons on the unit The unit can be operated manually or via a PC PLC Supplied accessories e Power cord e Inductor tool coil e User manual Optional accessories e External water cooler e Trolley e Custom inductors e Workstation with a balancer e Transport box e Water pump e IR sensor for Temperature control e Machine fitting e Deck Heater e Flex Heater e Push button cable Handling During Transport e The unit contains sensitive electronic components and it is not shock resistant never drop the unit e Save the original packaging for safe transport e When transporting drain the water system with compressed air This is important to avoid frost damage Draining the Cooling Water Without cooler e Exit heating e Turn off the water supply e Replace the water with compressed air in inlet e Blow out all the water With cooler e Exit heating e Shut off the cooler e Blow compressed air in inlet
12. duct Diagnostics gt Alarms Ed Information The system has a memory when displaying the menu It remembers what parts of a menu was shown before So if you are in the Settings menu displaying the Max Power parameter and now navigate away from the Settings menu and then later back again it will display the Max Power parameter once again This memory is cleared when the system restarts Operation menu Below is a chart on how the Operation menu looks like Initially the four rows on the display show the four top squares Operation Power Desired Pwr Work Object Note Work Object is only present on machines with activated IR pyrometers If this is not the case then Resonant Current will be displayed instead With Arrow Down the list is scrolled downward so the display will show the list starting with Power instead see picture below More values can be displayed below Frequency see Menu Operation below Pressing Arrow Left or Arrow Right will leave the Operation Menu regardless what is currently displayed Picture showing what it looks like when the machine starts up Note the triangle in the top left corner Arrow on bottom left shows that more can be displayed below i he oat Hoots GB St LJ over os TE TRE ia Ei 1 g A an Et gua rE 2 te py de LE SS Kat Jes it bre ge i E L z LJ ae oe Ti Settings menu In the Settings menu you can re
13. from the coil People with pacemakers should never reside near magnetic fields Cleaning Make the unit powerless The unit should only be wiped with a damp cloth The coil is cleaned of soot and dirt to prevent electrical arcing Never rinse the unit since there is a risk that the water penetrates and destroys electronics Ventilation e All openings in the cabinet are for ventilation don t block or cover any of these it also applies under the unit e Never insert objects into these openings e Replace the air filter in the front of the unit at regular intervals to ensure air flow recommended replacement about 2 12 times a year depending on the environment Service e There are no parts that can be repaired by the user at failure contact the dealer LOTO Lock out tag out When the machine must be powered down for maintenance changing the coil or similar tasks even in this powered down state the machine is never to be opened up Pad Terminate any ongoing heating operation Turn off the main switch and lock it in its off position If the unit is delivered with a separate cooler that is power from a separate power source then turn off the main switch of the cooler too Turn off the water flow to the machine Now the work around the machine is ready to proceed Weekly maintenance Check the air filter change if needed Control the hose package for wear and tear injury If the system is equipped with IR pyrometer
14. nt Menu Operation No settings can be made in the Operation Menu Menu selection Comments Operation Power Displays IS value VA VoltAmpere Displays Should value in VA Work Object Temperature from connected Pyrometer Displays if not connected Not part of Limited version start of heating shows resonant frequency Resonant Shows the primary current May be limited at high current power output to avoid high resonant current peaks Program Select Display heating program to use Manual no program gt 1 heating program Chang in Settings gt Program Select Mains current Shows line current in A Ampere shows current program step time in program mode Operation time Displays the time the machine has been in operation heating time hhhh mm ss Menu Settings changes See below for manual operation Max Temp Work Object Temperature at which point the machine will disable heating for manual operation the temperature of the work object Max Resonant current Limit the resonant current to remove this limit set 0 The machine still has factory limitations that cannot be disabled Dependent on the material used Time cooling water After heating cooling water will still be active for this time Set O for continuous cooling applied Time Set the current time and date PLC Voltage Range Set the voltage range of the power control in the external control port O 10V or 0 20V Set Fan mode operati
15. olution Reboot Internal error requiring reboot Restart the machine EEPROM format err Cannot read parameter Contact dealer memory EEPROM incomplete Cannot read parameter Contact dealer memory EEPROM write error Error when storing parameters Regulator config Internal error Contact dealer 3V3 low voltage Internal monitoring of Check connected 24V low voltage externally supplied voltages equipment for short circuit 5V low voltage Check connected equipment If error persist contact dealer Regulator error 1 Internal error Contact dealer Regulator error 3 Internal error Contact dealer Regulator error 16 Internal error Contact dealer Regulator error 17 Heating stopped as phase error Check phases and fuses discovered Regulator error 18 Internal error Contact dealer Phase error Error on one or more phases Check phases and fuses Load error Heater cannot detect working Check coil and its coil connections Mains current rush Heating stopped because of Can occur if the unit large mains current detected comes too close to the resonance frequency Contact dealer High mains current Normally the heater can Should not occur under regulate the current to within normal operating Contact limits but for some reason has dealer now failed and finally cancelled heating Contactor released Contactor released during Check other errors heating Occurs together with other errors Need to set the unit in standby to be able to acknowledge
16. on Only IH5 model Off Always off Normal Controlled by water temperature Low Always on low speed High Always on high speed High Temp Alarm Set a temperature that the heater should set an external signal to indicate high temperature Not on all models This is the systems parameter used when program step data is not used Set to O if this should not be used No heat temperature amp When using a predefined program No heat time with temperature it is possible to set a temperature that the object that is heated should reach within a specified amount of time To disable set the time to O sec Temp Regulate P amp D Temp Reached Hyst amp Time PID regulator settings used when running temperature control programs This is the systems parameter used when program step data is not used The unit can signal when the desired temperature is reached on an external signal or on some pyrometer models on the display Here a delay of that signal can be set And an hysteresis allowing the temperature Min Frequency Start Current Network to drop without clearing the signal Set a low frequency that the system should work with Used very rarely this can limit the available output power of the system This is the system setting if no others are set in program Set a starting desired current that the system should try and reach Can make the system reach desired power faster Contact Incoil for m
17. ore information if needed This is the system setting if no others are set in program Select Static or DHCP network configuration Network settings not available on all models Contact distributor if unclear Panel Locked The data changeable in the Settings and Heating Programs panels can be locked to avoid changes by accident A four digit pin code is used to unlock the panel Setting the pin code to 0000 will allow the machine to start in unlocked mode basically a disabled lock However the panel can still be locked from this state and 0000 will have to be entered to unlock the machine or rebooting the machine To Lock the system from unlocked state Navigate to the Panel Locked setting and press the Down key Five rows of settings are now available Lock Unlock and the four digits in the pin code Change the first line to Lock and press Ok The panel is now locked If you change the pin code in the settings now the pin is NOT changed To change the pin see below To Unlock the system from locked state Navigate to the Panel Locked setting and press the Down key Five rows of settings are now available Lock Unlock and the four digits in the pin code The first line can be ignored The pin code will show only X s Using the Down Up arrow to select each digit and Left Right arrow to change the values set the correct pin code values and then press the OK key The system should now be unlocked and Unlock should be displayed
18. rature too high on Check incoming water water going out of the temperature if this may be machine Something may the cause generate too much heat Contact dealer Temp sensor rectif Empty coil No heat detected Prog Interrupt Temperature too high on internal rectifier IrTolmain setting has detected that the coil is running empty The temperature detected has not reached the correct temperature within the defined amount of time When configured that programs should not be interrupted but allowed to Internal electronics have become very hot should not occur unless some error Contact dealer Check that the coil is not empty Contact dealer for assistance if problem persist Make sure that the IR Pyrometer is correctly positioned Check if the object is inserted correctly into the coil Adjust the setting in Settings menu to reflect the correct temperature and or time Something stopped a running program when not allowed PC Connection Cannot reach Temp run thru Trying to start heating program without connection to PC when configured to demand connection Heating program Run To Temp or Temp Change programs was unable to reach the desired temperature Check PC connection program running Prog Needs Temp within the specified time limit Trying to start a program that requires that an pyrometer is present and is ok Check Pyrometer connector and setting Temp Sens
19. rder If the machine detects RTS then the phase changer should be in the other setting Not all machines Flow Monitor Shows if monitor detects water flow or not Flow Monitor Ext Shows if second monitor detects water flow or not Heating Switch Is Switch open or closed Temp sens WorkObj OK Not connected or Communication error IrTolmain Not all machines During operation shows the relationship between resonance current and mains current Can in some systems be used to detect that the coil is running without object to heat lpAddress Shows the machines Ip address not on all machines Menu Alarms In this menu active alarms are presented If more alarms are active than can be displayed then Arrow Up Down can be used to navigate the list of active alarms In order to be able to acknowledge an alarm the conditions that raised the alarms need to gO away Example Phase error then all three phases need to be restored to be able to acknowledge the alarm More than one alarm may be active at any time but only one will be flashing and is also displayed in the bottom row in all other menus Pressing OK button will acknowledge the current alarm But if the conditions for the alarms still apply then the alarm will still be active Acknowledged alarms will disappear from the list and if more than one active alarm then the next one will become flashing and can be acknowledged Message in the display Display text Comments S
20. read and be tightened with a torque 4 Nm to prevent leakage and provide good electrical contact Transforme O ring Coil Installation start up 1 Make sure that water of good quality example fresh water process water and electricity is available 2 Arrange the workplace so that no cables hoses or hose assembly is folded or squeezed 3 The coil should be mounted 4 Connect the water 5 Turn on the water 6 Check that there are no leaks Paragraph 4 6 does not apply if equipment supplied with preinstalled coolers 7 Make sure the main switch is turned off 8 Connect External Control external emergency circuit IR pyrometer and network if this is to be used 9 Plug in the power cord and turn on the main switch 10 Allow the machine to boot 11 Now press the button On Off to activate the heater and the cooling circuit 12 Let the water flow through the cooling circuit and lower the handle to prevent air pockets to be formed in the transformer coil especially important when replacing the coil if the machine has been drained of water or are unused 13 Check that no error message appears in the display window 14 The machine is now ready for heating a O CO ND Changing of the coil End heating turn off the power to the machine see Lock out Tag out above Loosen the nuts holding the coil Let the coil slide out of its mounting Water will flow out of the coil as it is filled
21. to control the machine using Modbus RS232 or TCP IP Program First define program to be run See Heating Programs in separate document When a button is pressed the program will start Releasing the button will NOT stop the program Pressing the button for a second time will stop the program Control panel full version FE Power potentiometer 3 Switch Panel Handle External X 4 Test power on 5 Panel contact ON OFF X Not currently used IR pyrometer 3 4 5 6 Green Heating Red Current limit Orange On 17 Green OK Red Error HO a 8 EH 15 E E E E X Option Menu structure of the control panel The menu consist of seven main pages where messages and measurements are presented settings can be reviewed and changed Operation Start mode that shows the most important measurements during normal operation Settings View current settings and make changes Heating Programs View and change programs to be run Not part of Limited L variant Temperatures Displays the monitored temperatures in the system Diagnostic Shows values not presented in operations menu Alarms Shows currently active alarms Alarms are acknowledged with the OK button and can be acknowledged regardless which menu is currently active Product Information Versions of the installed parts of the system Not presented in further details Operation Power Desired Power Work Object
22. with water This can be avoided by draining the cooling water see Draining the Cooling Water above Wipe up any water that runs out Check the coil and transformer according to Installation of the coil above Hold up the wings holding the coil and slide it into place Tighten the nuts with 4 Nm of torque Wipe up any water after the assembly Turn on the water flow again Make sure that no leakage occurs in the coil connection Continue with items 9 to 14 in Installation start up above 10 Check the water level of the cooler and fill up when needed Mains switch Do turn off the machine using the mains switch under high load First terminate any ongoing heating operation Only then use the mains switch to turn off the machine Functions The unit can be operated both manually and externally It can also be run with programs These can easily be created directly in the machine s display It is also possible to create programs on the PC and then transfer to the machine Version L Limited can only be run manually Manual Run startup procedure as defined previously Heating can now be started using Button 1 on display push button cable or handle button Control the power with potentiometer on the unit or on the handle Releasing the button stops the heating External Relay signals can start stop the unit Also show current status Ready to Heat Heating and Error signal It is also possible
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