Eldec is producing induction heating generators with a power range from 1.5KW up to 3MW. Power level is adjustable between 4 and 100%. Frequency range for audio frequency is between 8 and 40 kHz, high frequency for hardening is 150 – 350 kHz. The frequency is produced by transistors, feeding an oscillation circuit and is transferred to an output transformer for induction coils.
Warning signs:
2 2. Front view:
Output power in % Frequency in kHz depending
on induction coil 10-25 kHz
Heating start
Fault Reset
Power to inverter
Control voltage
The instruments on the front panel provide important data for fault diagnosis.
In the event of problems, always provide the eldec service employee with the device type and serial number of the generator and the values of power and frequency.
3 3. Mains connections: Eldec generators are generally designed for 3-phase 400 V~ +/-10%. They can be operated at both 50 Hz or 60 Hz. Right or left phase order doesn’t matter.
The device cannot be operated via a Residual Current circuit Breaker since all power components are water cooled and therefore currents - while heating - to ground are normal.
The serial number is written on the type plate on the rear side of the generator:
Serial number Mains fuse customer
4 4. Water connection:
1. Do only use clean water of a quality comparable to potable water.
2. Check filter strainer (located behind water supply connection). 3. Pressure gauge reading should be 4 to 6 bar (58 to 87 psi) while outlet is not pressurized. 4. Most devices work at a pressure of 3.5 bar (51psi). 5. Current flow rates can be shown in the display. 6. –BF0.1 designates the induction coil water flow. 7. The limit values for the individual water circuits can be reviewed in the display 8. The limit value for the inductor can be set in the inductor setup using the password K4340. 9. The supply temperature must be below 35°C (95°F). If temperature is higher, generator will switch off heating and show an error message: “water inlet temperature too high”. 10. If the cooling water is more than 10°C (18°F) colder than the air temper- ature humidity can condense on all water cooled components. This can cause arching and serious damage to the generator.
5 5. Inductor contacts: 1. with green rust 2. brown = heavily oxidized 3. lime deposits 4. clean and polished using fine-grain sandpaper With an MFG50, the contacts carry up to 4,000 amps!
Inductor connection on coaxial transformer:
Contact OK but O-rings missing
6 Inductor not inserted to mechanical stop => leak
Shrink hose insulation of coaxial transformer must be in good condition!
Otherwise there is a risk of electric shock!
It is recommended to wear protective gloves in order to avoid direct skin contact
with the inductor connections.
7 6. Switch and LED on output transformer: LED off: malfunction / not operational LED blinking: ready-to-operate LED on: generator is heating
8 7. Hose package of output transformer In case of water flow problems: Check hose package for kinks:
Cracked and porous hoses should be replaced by eldec.
Do not try to repair them by yourself, since there are wires inside the hoses you might damage.
9 8. How to remove a hose package with coaxial transformer !!! Before working inside the generator the mains has to be disconnected !!!
Do not remove hoses here!
Inside left side of cabinet towards the back side:
10 11 Please send the coaxial transformer like this to our company:
Coaxial transformer and hose package are in one piece and cannot be separated.
It’s a good idea to use an air gun to blow out the water out of the generator before disassembling the hose package.
Especially in wintertime, when you ship the generator to us for repair,
any water inside the generator can freeze and destroy the water cooled components.
12 9. General error messages
13 HSE Health, Safety, Security, Environment
The following work must only be performed by
trained electricians. The interior of the device carries lethally high voltage!
14 10. Full view of electrical side (right side):
Emergency-Stop safety relay Inverter block
Controlprint 24V power supply with transistors and driver board
Circuit breaker Fuses Main
disconnector
15 11. Control voltage cannot be switched on: Is the device connected to the mains? Are all three phases present with correct voltage? Are the automatic circuit-breakers activated? Is the display illuminated?
Switch off generator, disconnect from mains, wait for one
minute for the capacitors to discharge, then remove right housing cover. Check fuses using a digital multimeter or continuity tester.
16 12. Main disconnector cannot be switched on: Switch off the generator, remove the right-hand housing cover, switch on control voltage and visually inspect the following components:
Emergency stop safety relay “PNOZ” -E22.1 and -E22.2:
If these LEDs are on, the Emergency-Stop circuit is OK.
If not: ● Disengage the Emergency-Stop button at the front panel.
● Is the Emergency-Stop jumper wire present on terminal -X3.1? ● Disengage any external Emergency-Stop buttons.
=> Check cable connection between display and PLC.
Position of PLC inside cabinet:
18 Switch off generator and disconnect from mains. Wait one minute for the capacitors to discharge and remove right housing cover. Check plug connection at PLC and display. It may be necessary to unplug and reconnect it. The small switch left of the PLC plug must be set to RUN.
“POWER” and “RUN” LEDs must be on.
Top row of LEDs, designated “IN”, are inputs. Bottom row of LEDs, designated “OUT”, are outputs.
19 PLC fault indicators:
Battery discharged
PLC fault
In both fault cases, please contact eldec to determine further procedure.
Back-up battery beneath PLC cover:
20 Mitsubishi FX series PLC battery change Battery’s service life The battery’s service life is approximately 5 years. If the battery needs to be replaced, “Bat” is shown at the top left in the display. Battery type: for FX3u eldec article no. 89380358 Replacing the battery 1. Switch off the system’s power supply. 2. Remove top housing cover (Z). 3. Remove battery from bracket. 4. Disconnect the plug. 5. Plug in new battery. 6. Insert battery into bracket. 7. Replace top housing cover (Z).
To avoid data loss in the PLC RAM, replacing the battery must not take longer than 20 s.
The above is recommended by Mitsubishi.
As 20 seconds are a very short time, we recommend having
the battery replaced by a qualified electrician while the system remains powered in order to prevent entirely data loss.
Adjacent components that carry voltage must be covered.
Restarting the generator after replacement will remove the
“Bat” error message on the display.
21 14. Water side (left side):
Matching transformer Oscillating circuit
capacitors
Coaxial transformer Water counters
connection
22 The spare parts kit should contain the following components:
MFG50 with coaxial transformer:
Quantity Article Order no. 1 Button for handle of coaxial transformer 89130114 2 Coaxial transformer O-ring 89300020 2 M8 brass nut 89320039 2 M8 washer 89320041 2 Coaxial transformer clamping piece 83180009 1 13 mm open-end wrench 89430039 1 0.5 AF glass tube fuse 89140058 3 0.63 AT glass tube fuse 89140036 1 1 AT glass tube fuse 89140031 1 2.5 AT glass tube fuse 89140028 1 4 AT glass tube fuse 89140029 1 5 mm hex key 89430043 1 Water filter housing O-ring 89300016 1 Water supply filter 3/4" strainer 89290011 4 Stainless Steel Hose clamp 9mm 89270143 4 Stainless Steel Hose clamp ½” 89270144 4 Stainless Steel Hose clamp ¾” 89270145
1 Empty spare parts box 85950242
To conclude, we strongly recommend:
Please read the generator operating manual.
It contains important information about safety and how to
operate induction heating equipment. No worker should operate the generator without heaving read the manual.
