MINAC Series Single and Twin. Mobile Induction Heating Equipment PRODUCT DESCRIPTION

Transcription

1 Single and Twin Mobile Induction Heating Equipment PRODUCT DESCRIPTION Manufacturer: EFD Induction a.s P.O. Box 363, N-3701 Skien, Norway Tel: Fax: 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.

2 C O N T E N T S 1 INTRODUCTION MINAC Series MINAC 25 Twin TECHNICAL SPECIFICATIONS System MINAC 25/40, MINAC 25 Twin and MINAC 50/ Cooling Water Quality TECHNICAL DESCRIPTION System Description Modules and Electronic Cards Frequency Converter Output Current Limitations CAPacitor Hand Held Transformer EFD GROUP ADDRESSES... 8 Attachments Dwg C37854 MINAC 25S/Twin- MINAC 50, Layout Dwg C36158 HHT 240B/SS2 2x 2C, Layout for pistol grip, assembly Dwg C37990 HHT 400B/S1 4x 3C, Layout, Assembly drawing Dwg C37880 MINAC 25S/Twin- MINAC 50, Block diagram Dwg C37879 MINAC 25S/Twin- MINAC 50, Internal connections Dwg C37836 CON 1014S Converter, Circuit diagram (Single) Dwg C37829 CON 1014S Converter, Layout (Single) Dwg C36644 CON 1014T Converter, Circuit diagram (Twin) Dwg C37828 CON 1014T Converter, Layout (Twin) Dwg C37965 MINAC 25/40, Cooling water diagram Dwg C37881 MINAC 25Twin, Cooling water diagram Dwg C38014 MINAC 50/80, Cooling water diagram Dwg C32638 CCM 1006/1010 External control plugs, Circuit diagram Dwg C35598 MINAC, Interface signals, Time chart S Schedule of electrical equipment; MINAC 25/40 S Schedule of electrical equipment; MINAC 25 Twin S Schedule of electrical equipment; MINAC 50/80 Declaration of Conformity For reproduction rights, see cover page. Page i

3 1 INTRODUCTION 1.1 MINAC Series The MINAC series is a new generation of induction heaters consisting of the MINAC 25 standard and Twin, and standard 50/80 systems. The compact design of the equipment allows for easy portability and installation. The equipment offers rapid, concentrated and controlled heating with full repeatability. The MINAC has a wide range of induction heating applications including brazing and soldering, shrink fitting, hardening, curing, straightening and pre-/post-heating. The MINAC is suitable for heating many different electrically conductive materials. And the MINAC has integrated electronic impedance matching for optimal output power for various heating operations. The MINAC has a menu-based control panel. The control and communication system allows for the development of heat sequences and monitoring of power. The MINAC also offers control and data backup via field bus for operation in automatic lines and/or with robots. For external communication, the equipment can use the field-bus protocols Profibus DP, Interbus, Ethernet or others according to customer request. 1.2 MINAC 25 Twin The MINAC 25 Twin has two individual power outputs. The double output allows for independence of power levels, heating times and coil design. Figure 1. MINAC Single. Figure 2. MINAC 25 Twin. For reproduction rights, see cover page. Page 1

4 2 TECHNICAL SPECIFICATIONS 2.1 Standard system MINAC 25/40, MINAC 25 Twin and MINAC 50/80 Characteristic Supply Supply voltage range Frequency Nominal line current Max. line current at 360 V Nominal apparent power Maximum apparent power Power factor (cos Ν) Recommended fuse * Mains cable length Output Nominal output power DC power, intermittent duty Duty factor/cycle time Output power regulation range Frequency range Efficiency HHT power cable length Cooling Water consumption, min. Water inlet temperature Water pressure min./max. Ambient operating temp. Enclosure Outer dimensions, (WxDxH) Weight Enclosure protection Color Specification MINAC 25/40(-400) MINAC 25 Twin MINAC 50/ V ±10% 45A (RMS) 68A (RMS) 31 kva 45 kva 63 A 25 kw 40 kw 12 l/min (20 l/min) 4/6 bar V ±10% 90A (RMS) 135A (RMS) 62 kva 90 kva 100 A 2x25 kw 2x40 kw 24 l/min 4.5**/6 bar V ±10% 90A (RMS) 135A (RMS) 62 kva 90 kva 100 A 50 kw 80 kw 22 l/min 4/6 bar * Fuse: gl Characteristics. ** 5.5 bar with 10m HHTs connected. For reproduction rights, see cover page. Page 2

5 2.2 Extended power range system If the units are to be connected to a 480V supply line only, extended power range units are available MINAC 30/50, MINAC 30 Twin and MINAC 60/100 Characteristic Supply Supply voltage range Frequency Nominal line current Max. line current at 456 V Nominal apparent power Maximum apparent power Power factor (cos Ν) * Recommended fuse Mains cable length Output Nominal output power DC power, intermittent duty Duty factor/cycle time Output power regulation range Frequency range Efficiency HHT power cable length Cooling Water consumption, min. Water inlet temperature Water pressure min./max. Ambient operating temp. Enclosure Outer dimensions, (WxDxH) Weight Enclosure protection Color Specification MINAC 30/50(-400) MINAC 30 Twin MINAC 60/ V 5%/+10% 44A (RMS) 70A (RMS) 37 kva 55 kva 60 A 30 kw 50 kw 12 l/min (20 l/min) 4/6 bar 480 V 5%/+10% 88A (RMS) 140A (RMS) 74 kva 110 kva 125 A 2x30 kw 2x50 kw 24 l/min 4,5/6 bar 480 V 5%/+10% 88A (RMS) 140A (RMS) 74 kva 110 kva 125 A 60 kw 100 kw 22 l/min 4/6 bar * Fuse: Class J Characteristics For reproduction rights, see cover page. Page 3

6 2.2 Cooling Water Quality The quality of the cooling water for all of the MINAC systems should have the following purity: Characteristic Specification PH between 7.0 and 9.0 chloride content [CI] nitrate content [NO 3 ] sulfate content [SO 4 ] total solids content total hardness, as calcium carbonate [CaCO 3 ] 20 ppm 10 ppm 100 ppm 250 ppm 250 ppm Clean tap water can be used when there is no risk of freezing. Normally, an electrical resistivity measurement of the water will provide a satisfactory guide to the total amount of dissolved solids. Water having a resistivity 25 Om or a conductivity 0.04 S/m (400µS/cm) measured at 25 C is usually satisfactory as a coolant. If the cooling water has a content of calcium carbonates higher than 250 ppm, the cooling water system must be decalcified regularly. For reproduction rights, see cover page. Page 4

7 3 TECHNICAL DESCRIPTION 3.1 System Description The MINAC induction heating systems consists of three major units: Frequency converters FC 25, FC 25 Twin or FC 50 Output capacitor CAP1211i Hand held transformer HHT 240S2-2x16T-2C or HHT 400-4x8T-3C Other types of CAP and HHT are available on request. The resonance circuit, i.e., the coil inductance and the resonance capacitor bank, gives the output current frequency. The control system adjusts the inverter switching frequency to match the resonance frequency. Thus, maximum performance from the equipment is always achieved. The MINAC inverters have the following nominal power output current and nominal power output impedance ratios: Nominal power reached at: Equipment Nominal output current Ratio to nominal output current Ratio to range of output impedance FC 25/40 36% 2.8:1 7.8:1 FC 25 Twin 36% 2.8:1 7.8:1 FC 50/80 36% 2.8:1 7.8:1 The flexibility in accepting variable load impedance without reduction of output power is called automatic matching. Variations in output impedance are due to change of coils, different workpieces and increases in temperature, among other factors. Control and operation of the equipment are primarily from the unit s operating panel that serves as the man-machine interface (MMI). The local power on/off circuit can also be operated from the button on the HHT handle or the foot controller. Different types of external control units can be used to operate the frequency converter by connection via the signal plug socket on the back of the converter. For reproduction rights, see cover page. Page 5

8 3.1.1 Modules and Electronic Cards The induction heating system consists of the following modules and electronic cards: Abbrev. Module/component Subcomponent/electronic card CHS Chassis module Contains all other modules. CON Converter module Contains the rectifier, inverter and the el. card FVCM. OPN Operating panel Functions as the Man-Machine-Interface (MMI). ELR Electronics rack Contains the electronic cards MECC (Motherboard), MBAC, CIES, SMPS, POWS, FIPX and MCCC. CAP Capacitor module Contains the output resonance capacitor bank. HHT Hand held transformer CAB Cable module Contains all cables interconnecting other modules. 3.2 Frequency Converter The single and twin frequency converters that MINAC 25/40, MINAC 25 Twin and MINAC 50/80 are based on are designed for use in a wide range of induction heating applications. The MINAC is small and lightweight, but has high power and variable frequency ranges. It is adaptable to a variety of processes, including mobile brazing, hardening and general heat treatment. It has a modular design to ensure fast and simple on-site servicing. The MINAC is indirectly water-cooled and has a diode rectifier and full-bridge IGBT transistor inverter. The MINAC is delivered with the following 5m-long main power cables: MINAC 25/40 16 mm 2 MINAC Twin 2m 2 MINAC 50/80 2m 2 The cables are equipped with a connection plug that also functions as a main power disconnector. The main power cable is connected to the high-speed fuses and EMI filter, and then to the main switch that also functions as an emergency stop switch (red/ yellow), and further to the rectifier diodes. The electronics power supply branches off after the main switch and feeds through a 3 x 500/220 V transformer to the SMPS card. The SMPS card and POWS card supply the cooling fans, solenoid valve and electronics with regulated voltages. This system allows the unit to operate on a wide range of input voltages. The main voltage is rectified by a 6-pulse diode rectifier and fed to the inverter section through an LC filter. The LC filter blocks return of the high frequency inverter currents to the supply. In addition, a capacitor bank is connected across the inverter For reproduction rights, see cover page. Page 6

9 module terminals in the MINAC single and each set of inverter module terminals in the MINAC twin. The inverter generates the 10 40kHz AC output current Output Current Limitations The output current of the IGBT converters is adjustable between minimum and maximum levels. The minimum level is determined by the design of the converter and depends on the actual load. The maximum level depends on the output frequency. At low frequencies, output current is limited by the compensating capacitor's maximum voltage and the transformer's saturation voltage. At high frequencies the limitation of the output current is due to frequency dependant losses (switching losses, etc.). As long as a POWER ON signal is given, the output power will never be zero, although the reference set point may be set at zero. This means that a small output current runs through the induction coil, and is because the frequency converter's regulation system needs some current feedback to function. 3.3 CAPacitor The Capacitor module (CAP) is a series compensation unit that produces the necessary reactive power needed in the load through a resonance capacitor bank. It is located behind the right side cover (as seen from front). The resonance capacitor bank is water-cooled, as are the terminals for the output connections (the HHT connections). 3.4 Hand Held Transformer The Hand Held Transformer (HHT) is connected to the CAP module through watercooled flexible cables with an optional length of 5 or 10 m. In some deliveries, the HHT can be equipped with holding brackets, or fixed to a machine or a specially made fixture. The holding brackets can be equipped with an on/off button. The ratio of the transformer is determined by the application the induction heating system is used for. The HHT can be used to heat magnetic and non-magnetic materials. This HHT is used for heat treatment, forging and brazing. Another type of HHT might be considered for hardening. The coil output voltage depends on the output power, and the length and design of the coil. The correct selection regarding type of HHT for every specific application can only be made once all information regarding the intended application is available. If a very large induction coil or a multi-turn coil is needed for the application, an HHT with a different transformer must be used. Each HHT has a serial number and certificate. For reproduction rights, see cover page. Page 7

10 4 EFD GROUP ADDRESSES EFD-ASA, Norway-Germany Manufacturing Companies Sales and Service Companies EFD Induction a.s EFD Induction Ges.m.b.H. Bøleveien 10 Vogtgasse 28 Postboks 363 Sentrum A-1140 Wien, Austria N-3701 Skien, Norway Tel Tel Fax Fax EFD Induction s.l. EFD Induction GmbH Los Palangreros No. 5 Lehener Strasse 91 (Trasera) Entreplanta Postfach 426 E Portugalete (Vizkaya), Spain D Freiburg, Germany Tel Tel Fax Fax EFD Induction s.r.l. Lohnhärterei, Fritz Düsseldorf GmbH Via Sirtori, 15 Bebelstrasse 9 I Monza, MI, Italy D Freiburg, Germany Tel Tel Fax Fax EFD Induction AB EFD Induction S.A. Kokillgatan 3 20, avenue de Grenoble Box B.P. 30 S Västerås, Sweden Seyssinet-Pariset Tel Cedex, France Fax Tel Fax EFD Induction, Inc Dequindre Rd. Sodalgo S.A. Madison Heights, MI 48071, USA Z.I. du Fond des Prés Tel Marcoussis, France Fax Tel Fax Cedipac Co., Ltd. Room 1209 Union Plaza EFD Induction Ltd. No. 20 Chao Wai Da Jie Plot No. 16 C & D, KIADB Industrial Area, Attibele Chaoyang District Bangalore , India Beijing , China Tel Tel Fax Fax EFD Induction Ltd. Units 1&2, Wednesfield Way Industrial Estate Well Lane, Wednesfield Wolverhampton, WV11 1XP, UK Tel Fax EFD Induction (Shanghai) Co., Ltd. Bldg. C, No. 679 Shen Fu Road Xin Zhuang Industrial Park Shanghai , China Tel Fax For reproduction rights, see cover page. Page 8