1 - User Manual Sinac 6-50 Rev B - EN

SINAC®
UNIVERSAL
HEAT
GENERATOR
User Manual
Sinac 6–50 Series

Volume 1 | Document 00139398 | Rev. B.
ABBREVIATIONS
CAP = Output Capacitor
CCM = Customer Communication Modules
CON = Converter Module
ECU = External Control Unit
ELR = Electronic Rack
EOR = Extended Operating Range
FC = Frequency Converter
HF = High Frequency
HHT = Hand Held Transformer
HS = Heating Station
IGBT = Insulated Gate Bipolar Transistor
ITFS = Interface to Flow Sensor
MF = Medium Frequency
Minac = Product name for the induction heating system
MMI = Man-Machine Interface
OMM = Output Matching Module
OPN = Operating Panel
PE = Protective Earth
QR = Quick Release
Sinac Product name for the induction heating system
SH = Serial Compensated High Frequency
SM = Serial Compensated Medium Frequency
SL = Serial Compensated Low Frequency
WCPS = Water Cooling Pump Station
CONTENTS
1 INTRODUCTION................................................................................................................. 1
1.1 Induction Heating ......................................................................................................... 1
2 GUARANTEE CONDITIONS .............................................................................................. 2
2.1 Restrictions in Use ....................................................................................................... 2
2.2 Qualified Personnel...................................................................................................... 3
3 SAFETY INSTRUCTIONS .................................................................................................. 4
3.1 Safety Signs ................................................................................................................. 4
3.2 General......................................................................................................................... 5
3.3 Electric Shocks............................................................................................................. 5
3.4 Heated Objects ............................................................................................................ 6
3.5 Electromagnetic Fields................................................................................................. 7
3.6 Touching the Induction Coil on Manually Operated Equipment................................... 7
3.7 Touch Voltage at the Coil ............................................................................................. 8
4 TRANSPORT, STORAGE AND RECYCLING / DISPOSAL............................................... 9
4.1 Transport ...................................................................................................................... 9
4.2 Storage......................................................................................................................... 9
4.3 Recycling / Disposal................................................................................................... 10
5 INSTALLATION ..................................................................................................................11
5.1 Unpacking the System ................................................................................................11
5.1.1 Lifting the Equipment with Hoisting Belts .....................................................11
5.2 Mounting the Sinac .................................................................................................... 12
5.2.1 Cabinet Attached to a Frame (Optional) ..................................................... 13
5.3 Connection to Power and Water Supplies ................................................................. 13
5.4 Power Connection...................................................................................................... 14
5.5 Cooling Water Connection ......................................................................................... 15
5.6 Cooling Water Quality ................................................................................................ 16
5.7 External Interface Signals .......................................................................................... 17
5.8 System Grounding Principles .................................................................................... 17
5.8.1 High Frequency Induction Equipment and Grounding................................ 17
5.8.2 Installation Guidelines ................................................................................. 18
6 CONNECTING AND USING THE COIL ........................................................................... 20
7 SYSTEM DESCRIPTION.................................................................................................. 21
7.1 Frequency Converter ................................................................................................. 21
7.1.1 Control Panel............................................................................................... 22
7.2 Output Current Limitations ......................................................................................... 22
7.3 Output Unit ................................................................................................................. 23
7.3.1 Hand Held Transformer (HHT) .................................................................... 23
7.4 Distribution Network Requirements ........................................................................... 23
7.5 Interface and External Control ................................................................................... 23
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7.6 Performance Level ..................................................................................................... 24
8 OPERATING THE CONTROL PANEL.............................................................................. 25
8.1 Operating Panel (OPN) .............................................................................................. 25
8.1.1 Display and Keyboard ................................................................................. 25
8.1.2 Operating Switches and Indicators ............................................................. 27
9 OPERATION...................................................................................................................... 28
9.1 Before Starting ........................................................................................................... 28
9.2 Start............................................................................................................................ 28
9.2.1 Programming the MMI................................................................................. 29
9.2.2 Output Power Control.................................................................................. 30
9.2.3 Alarms Indication ......................................................................................... 32
9.3 Output Power ............................................................................................................. 33
9.4 Distance to Workpiece ............................................................................................... 33
9.5 Normal Stop ............................................................................................................... 34
9.6 Emergency Stop/External Stop Command................................................................ 34
9.7 Restart after Emergency Stop/External Stop Command........................................... 34
10 OPERATIONAL INFORMATION....................................................................................... 35
10.1Control Function......................................................................................................... 35
10.2Power on Command .................................................................................................. 36
10.3Footer Messages ....................................................................................................... 37
11 MENUS.............................................................................................................................. 39
11.1 Activate Menu (menu 2) ............................................................................................. 40
11.2 PIN Code Menu (menu 26) ........................................................................................ 40
11.3 Change PIN Code Menu (menu 27) .......................................................................... 41
11.4 Setpoint Menu (menu 3)............................................................................................. 41
11.5 Timer Menu (menu 7)................................................................................................. 42
11.6 Sequence Menu (menu 4) ......................................................................................... 42
11.7 Energy Menu (menu 8) .............................................................................................. 43
11.8 Event Output Menu .................................................................................................... 45
11.9 Display Values (menu 24) .......................................................................................... 45
11.10Display All Values (menu 19).................................................................................... 46
11.11Display Timer/Sequence (menu 23) ......................................................................... 46
11.12Twin Display Values (menu 36) (Only Twin/Dual units) ........................................... 46
11.13Status Info. (menu 29) .............................................................................................. 46
11.14Ethernet IP Addr. (menu 39) (optional)..................................................................... 47
12 MAINTENANCE ................................................................................................................ 48
12.1Cooling System .......................................................................................................... 48
12.1.1 Cleaning Additives....................................................................................... 49
12.2Safety Regulations ..................................................................................................... 50
12.3Daily Inspections ........................................................................................................ 50
12.4Routine Maintenance ................................................................................................. 50
12.4.1 14 Days Inspection ...................................................................................... 51
12.4.2 Semi-Annual Inspections ............................................................................ 51
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12.5Bolts, Nuts and Washers............................................................................................ 52
13 DISTURBANCE OF OPERATION AND CORRECTIVE MEASURES ............................. 53
13.1Alarm Messages ........................................................................................................ 54
14 REGISTRATION FORM FOR FAULT FINDING ............................................................... 60
15 EFD INDUCTION ADDRESSES....................................................................................... 61
Document 00139398 | Rev. B. | September 27, 2017 Page iii www.efd-induction.com

INTRODUCTION
1 INTRODUCTION
The Sinac, frequency converter (FC), documentation is divided into two volumes: User Manual
and Technical Description.
Manual structure:
Volume 1, User Manual: Contains guarantee conditions, restrictions in use, qualified person-
nel, safety instructions and system description. This volume contains instructions on how to
transport, store, install, operate and maintain the equipment. Read the volume thoroughly,
understand and follow the instructions before using the induction heating equipment. For prod-
uct specific figures and drawings, refer to volume 2, Technical Description.
Volume 2, Technical Description: Contains a technical specification table with all the vital fig-
ures and measurements for the equipment. This volume also has a drawing section and a cus-
tomer optional equipment section with additional drawings.
Using the manual, on-site qualified personnel can setup the equipment for operation, under-
take the daily operation of the equipment, and perform maintenance and simple repairs. In the
event of more serious repairs or a breakdown, contact EFD Induction a.s or any EFD Induction
Group company/agent.
All reasonable efforts have been made to ensure the accuracy of the con-
tents of this technical manual. However, the manual may contain clerical
errors or misprints.
1.1 Induction Heating

The compact design of the Sinac induction heating equipment allows for easy installation and
offers rapid, concentrated and controlled heating with full repeatability.
The induction heating equipment has a wide range of induction heating applications including
brazing and soldering, shrink fitting, hardening, curing, straightening and pre-/post heating.
The Sinac series is suitable for heating many different electrically conductive materials, and
has integrated electronic impedance matching for optimal output power for various heating op-
erations. The menu-based control and communication system allows for the development of
heat sequences and monitoring of power. Optionally, the series also offers control and data
backup via field-bus for operation in automatic lines and/or with robotic assembly. For external
communication, the equipment can use the field-bus protocols Profibus DP, Devicenet, Ether-
net or others according to customer request, when ordering new equipment. The Twin version
has two individual power outputs. The double output allows for independence of power levels,
heating times and coil design.
Document 00139398 | Rev. B. | September 27, 2017 Page 1 www.efd-induction.com

GUARANTEE CONDITIONS
2 GUARANTEE CONDITIONS
Induction heating equipment is a high-technology system for industrial use, to be used by
qualified personnel in accordance with the Technical Handbook. It is important to comply
with the safety measures set out in these manuals to avoid injury to persons, or dam-
age to equipment and surroundings.
EFD Induction equipment is in conformity with all of the applicable standards such as: Electro-
magnetic compatibility (EMC) and Industrial, scientific and medical (ISM). The Declaration of
Conformity is located as an attachment to the volume, Technical Description.
Before operating the equipment, qualified personnel will install it in accordance with the instal-
lation instructions.
Regular inspection and maintenance are required and only genuine recommended spare parts
should be used. Maintenance will be carried out by qualified personnel in accordance with the
maintenance instructions.
The guarantee conditions form is a part of the contract documents for the equipment. Some
conditions are repeated below to emphasize the importance of the supplier's guarantee
conditions.
• EFD Induction guarantees that its products will be free of defects in design, materials and
workmanship for a period of 12 months after commission or 18 months from the delivery
date, whichever comes first. If a product proves defective during this guarantee period,
EFD Induction, at their preferences, will either repair the defective product without charge
for parts and labour, or provide a replacement in exchange for the defective product.
• To obtain service under this guarantee, notify an EFD Induction supplier or EFD Induction
a.s. of the defect before the expiration of the guarantee period, and make suitable arrange-
ments for the performance of service.
• Induction coils are heating tools and are not covered by this guarantee.
The guarantee does not apply to any defect, failure, or damage caused by improper use, or im-
proper/inadequate maintenance and care.
2.1 Restrictions in Use

Take great care when using the equipment. It is intended for industrial induction heating appli-
cations. Only electrically conductive materials can be heated. The presence of combustible
materials involves a risk of fire.
The output power for the Sinac is listed in volume 2, Technical Description. The output power
is given at the output on the primary side of the HHT transformer. The DC power is displayed
on the LCD screen.
The values listed in volume 2, Technical Description, are at nominal input voltage, with speci-
fied matching ratio and nominal frequency range. For higher input voltages and less impe-
dance ratio, continuous output power can be higher. For detailed data, contact EFD Induction.

GUARANTEE CONDITIONS
2.2 Qualified Personnel

The system must be operated and maintained by trained and qualified technical personnel.
Qualification of personnel is in accordance with IEC standards.
• Skilled: individual who has read and understands the manuals with a recognized degree,
certificate, or professional standing and relevant technical education, training and/or experi-
ence enabling him or her to demonstrate the ability to solve or resolve problems relating to
the subject matter, the work, or the project.
• Instructed/Trained: individual who has read and understands the manuals and/or has par-
ticipated in training sessions on technical and operating instructions.
Qualified Personnel Instructed Skilled
Setup X
Operation X
Maintenance X X

SAFETY INSTRUCTIONS
3 SAFETY INSTRUCTIONS
Read and understand this manual. Only qualified personnel can operate or service the
equipment.
To prevent serious personal injury and/or damage to equipment and surroundings, comply with
all safety instructions.
Accidents occurring during the use of induction equipment are seldom. However, misuse of
equipment can lead to damage or personal injury. Safety instructions, including important infor-
mation on the risks associated with specific operations, and recommendations on suitable pre-
cautions, are found throughout the manual.
3.1 Safety Signs

The International Standard, ISO 7010, prescribes safety signs for the purpose of accident pre-
vention, and is applicable to all locations where safety issues related to people need to be ad-
dressed. Refer to www.iso.org for more information.
Safety signs used in the manual are categorized according to their function as follows:
Mandatory action sign is a blue circle with a subject icon. Follow the in-
structions given with the mandatory sign.
Prohibition sign is a red and white circle, with a red line over the icon. The
sign and text signify a prohibited action.
Warning sign is a yellow triangle with black outline. The text DAN-
GER, WARNING and CAUTION classify the severeness, with DAN-
GER as the most severe.
Information, or notice, provides additional information to a particular para-

graph regarding equipment or procedures. This sign is not part of the ISO
7010 graphical symbols.

SAFETY INSTRUCTIONS
3.2 General
Safety precautions must be observed during all phases of operation and maintenance. Failure
to comply with these precautions, or with specific admonitions given elsewhere in this manual,
is a violation of the safety standards of the design, manufacture, and intended use of the
equipment.
Anyone operating, maintaining, or working in close proximity to the equip-

ment MUST thoroughly read, understand, and obey the safety instruc-
tions set out in this manual. Only qualified personnel who are familiar with
the Technical Handbook can be permitted to maintain this equipment.
Please note the following:
The equipment has either a front door or screw-fastened covers. The door/covers must not be
opened when the equipment is connected to the main power supply. Only skilled qualified per-
sonnel can service the equipment.
Disconnect the main power supply when the equipment is not in use, and
always prior to repair or maintenance. Follow the maintenance
instructions.
The personnel protective equipment (PPE) recommended for users are

dry, undamaged, non-conductive gloves and safety glasses.
Always comply with all safety measures when handling electrical equip-
ment, including any national or international regulations. Users are also
required to follow their company’s safety regulations.
3.3 Electric Shocks
DANGER! Electrical shocks can result in personal injury or loss of

life. The equipment door/cover is marked with an electrical warning
sign label.

SAFETY INSTRUCTIONS
To avoid the risk of an electric shock:
Do not open the equipment covers when connected to the main power
supply.
Do not cut or damage the supply cables to the frequency converter.
Do not open the equipment covers during maintenance without setting

the main power disconnector in the OFF position, and disconnecting the
main power supply.
Touching the induction coil or coil adapter can cause discomfort or even
be painful, but it will NOT cause any personal injury or loss of life. See
section 3.6 Touching the Induction Coil on Manually Operated
Equipment.
3.4 Heated Objects
WARNING! Heated objects can cause fire or burns.
The principle of induction heating is based on an alternating electrical current flowing through
a coil which generates an electromagnetic field that varies in magnitude with the current. When
an electrically conductive material is placed inside the coil, eddy currents will be induced in the
material. Due to the resistance of the conductive material, heat is developed in the region of
the material through which the eddy currents flow. Induction heating equipment can heat elec-
trically conductive materials to a very high temperature in a short time.
To prevent the danger of fire or burns:
Do not come in direct contact with heated objects, the induction coil, and
the coil adapter terminals before they have cooled.
Do not use or keep any combustible materials near the work area or
heated objects.
Do not wear or have metal objects about your body while operating,
maintaining, or being in the presence of the induction equipment when it
is in use.

SAFETY INSTRUCTIONS
3.5 Electromagnetic Fields
CAUTION! 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. An electromagnetic field’s strength decreases with the square of the distance from the
coil.
To avoid hazards to personal health:
Persons with pacemakers, heart valves or metal pins, plates or other

bone joining devices, should avoid exposure to induction coils or areas
with strong magnetic fields. The equipment is also marked with a pace-
maker label to underline the importance of this matter.
Anyone with an implant, regardless of type, or pregnancy should consult

a physician about the effects of high-frequency electromagnetic fields.
In general, all personnel should take great care not to come too close to the induction coil
when the equipment is in operation.
3.6 Touching the Induction Coil on Manually Operated Equipment

Induction heating takes place by using electricity directly in the work process, comparable to
electric arc welding. When electricity is used this always involves a risk of accidental contact
with living parts. The voltage and frequency employed are at a level that does NOT cause any
personnel injury or loss of life. Touching the induction coil or coil adapter can cause discomfort
or even be painful. The operators should be qualified personnel that are aware of this situation.
It is important to emphasize that voltages at the frequency of the utility grid (50 or 60Hz) pro-
vides a much higher risk of permanent injuries than at the frequencies employed in the coils of
EFD Induction’s hand held equipment.
International standards for permissible touch voltages at frequencies above 1 kHz are present-
ly inadequate, but they are under preparation.

SAFETY INSTRUCTIONS
Using dry, undamaged, non-conductive gloves is recommended when

manually operating the equipment. Also some induction coils have an in-
sulating coating which provides improved protection.
The equipment must be grounded, and the equipment grounding system

must be intact. There must be a continuous ground connection between
the induction coil and the operator’s workplace. This can be checked us-
ing an Ohm-meter before the equipment is turned on.
3.7 Touch Voltage at the Coil

The impact of electric current through human tissue varies with the frequency and the strength
of the current. Low frequencies can produce irreversible heart fibrillations, and convulsive
muscle effects. These effects will dissipate at higher frequencies.
In the medium frequency range where Sinacs operate, the body can sense the current with a
finger contact of 30-40V. The feeling starts as a tingling effect, and with increasing voltage it
becomes an unpleasant feeling. In the voltage range of 60-80V, the sense of feeling is painful,
and results in an immediate body retract. There will not be any injuries after body retraction,
and there will not be any need for medical aid.
Higher voltages can cause paralysing effects localized to the muscles where the current flows,
but there will not be any convulsive effects, because the body will have the possibility to retract
from contact with the voltage. These voltages will not be reached in the Sinac, unless tools are
used to open the covers on the Sinac.
Operators of the equipment must be aware of the risk for unpleasant feeling of an inadvertent
touch to this voltage, and care shall be taken to avoid this occurrence.
Only use the equipment with dry isolating gloves without any defects. Al-
so induction coils with an insulating coating can be used.
Special care shall be taken in operations, where secondary effects from reactions from inad-
vertent contact can result in a dangerous situation, like operations in rooms with narrow
spaces, or where the operator is on the top of a ladder or standing on unsafe ground.

TRANSPORT, STORAGE AND RECYCLING / DISPOSAL
4 TRANSPORT, STORAGE AND RECYCLING / DISPOSAL

4.1 Transport
Transport the wooden crate with a forklift or lift it with a crane. With the use of a crane, lay
hoisting belts under the crate. Lift EFD Induction equipment only while it is in the shipping box.
DANGER OF DAMAGE with improper transport. DO NOT lay the

wooden crate on its side!
WARNING! Never stand under load while lifting!
Figure 4–1 Lifting by crane.
4.2 Storage
The equipment can be stored for longer periods of time if kept in the shipping box. Do not re-
move the packaging.
The storage area should be dry and air-conditioned or heated, with temperatures between 0°C
and 55°C (32°F and 131°F).
If the Sinac is stored in temperatures below freezing, first flush the water system with anti-
freeze fluid (depending on temperature, the water mixed with up to 35% of Monopropylene

TRANSPORT, STORAGE AND RECYCLING / DISPOSAL
glycol (MPG) type). Then drain the water system by using pressurized air. Antifreeze is neces-
sary even when the Sinac is in storage because there will always be some fluid left in the sys-
tem. DO NOT store below –25°C.
Systems shipped from Norway in winter time are prepared for transport and storage in freezing
temperatures. Store the system as shown in the crate.
4.3 Recycling / Disposal

The induction heating equipment is categorized as an industrial electric device. Recycling and
disposal should be in accordance to all applicable national and regional regulations.
The collection, treatment and recycling of electric devices is extremely

important to the improvement of the environment, economy, and
resources.

INSTALLATION
5 INSTALLATION
5.1 Unpacking the System
• To unpack the system from the crate, first re-
move the crate lid.
• Remove packing foam and plastic.
• Check the content of the crate against the
specifications on the delivery note.
• Remove loose parts. Power cables (optional),
output transformer and other items attached to Fig. 5–1 Removal of crate lid.
the Sinac should be placed outside the crate to
free the space at the bottom of the Sinac/crate.
5.1.1 Lifting the Equipment with Hoisting Belts

• Using a forklift or a crane, lift the Sinac out of the crate. Guide the hoisting belts through the
hoisting eyebolts and secure.
• Use all lifting eyebolts
• Estimate the load according to the combination angle table below.
With systematic distribution of the load, the

following overall loads are permissible:
90° 60° 45°

2 x 2000N or
3200 N or 326.3 2400 N or 244.7
Lifting loads for Sinac 6–50 in small cabinets 203.9 kg (4000
kg kg
N or 407.8 kg)

INSTALLATION
Avoid damaging the connections

• The Sinac is attached to the crate by screws
going through the top mounting brackets.
• Start lifting. The Sinac and crate will tilt up-
wards together. Stop lifting once the hoisting
belts touch the top of the crate. This will give
access to under the crate for removing the top
of the crate.
• Unscrew and remove the top of the crate.
• Lift until vertical.
• Remove the remainder of the crate by un-
screwing the screws going through the mount-
ing brackets.
• The frequency converter is now free to be
placed in the desired mounting area.
CAUTION! DO NOT stand the crate

vertically without the support of
hoisting belts. The crate is not de-
signed to support the weight of the
Sinac by only the screws going
through the mounting brackets.
Fig. 5–2 Step by step instructions for unpacking
5.2 Mounting the Sinac

When determining the location to mount the Sinac, the free space in front of the equipment
must be considered. The area must be clear to open the cabinet door and inner door.
Figure 5–3 Sinac free space needed.

INSTALLATION
The Sinac comes with 4 standard mounting brackets suitable ONLY for stationary installation
(static loads). Use all 4 brackets with symmetrical loading. For non-stationary/mobile installa-
tion (dynamic loads), the Sinac must be installed with additional mounting support.
Figure 5–4 Sinac mounting brackets.
5.2.1 Cabinet Attached to a Frame (Optional)

The frame is only designed to be mounted with
the Sinac induction cabinet. Do NOT mount any
other equipment on to the frame. This can lead to
the instability of the frame and damage to the
Sinac.
Extendable support legs are equipped on the

frame to be used only temporarily during service
or transportation. To lock the support legs make
sure to tighten the knobs.
To prevent the frame with cabinet from tipping

over, the frame must be anchored to the floor and
wall with 6 x M8 8.8 quality screws.
See mounting drawing attached in volume 2,

Technical Description. Fig. 5–5 Mounting frame for small cabinets
5.3 Connection to Power and Water Supplies

Required parts
• Power cable, suitable for local power connection (only when the power cable is not included
in the delivery or it is not suitable).
• Two 19mm (3/4-inch) water hoses for connection to the Sinac for the cooling water. The
hose nipples 19mm (3/4-inch) are connected to the Sinac with R 3/4-inch threads.
• Mains disconnecting device when the standard Sinac main switch handle is not installed on
the Sinac.

INSTALLATION
5.4 Power Connection

• If the power cable is not ready-installed at delivery, connect the power cable to the main
switch.
• Connection of the Sinac is independent of the direction of rotation of the 3-phase system.
• The standard Sinac is equipped with a main-switch handle. If the Sinac main switch is not
installed, then the Sinac could be a part of a system with a main switch for the system. If the
Sinac is not part of a system then the customer should have a mains disconnecting device
on the mains supply.
• Ensure that the mains supply voltage is according to the values given in the Sinac technical
specification, see rating plate on the equipment.
• For the mains supply fuse, see the technical specification in volume 2, Technical
Description.
• To avoid damage to the HHT and hoses, follow the instructions on the HHT Mounting Layout
attached in volume 2, Technical Description.
• Connect an induction coil to the output transformer.
CAUTION! CORRECT VOLTAGE: Make sure that the supply voltage

matches the specifications.
PROTECTIVE GROUNDING: To avoid electric shocks, make sure the

protective grounding conductor for the main power cable is connected to
ground.

INSTALLATION
5.5 Cooling Water Connection

• Connect the cooling water hoses to the system’s water inlet and outlet.
• Check to ensure that these connections have been secured correctly to the right attach-
ments. See cooling water connection drawing attached in volume 2, Technical Description.
• Check that the external cooling water circuit is ready for use (pumps, external valves open,
etc.) and that the inlet water temperature is below 35°C/95°F or at 20°C +/- dependent on
the dew point. If the inlet water temperature is at or below the dew point then condensation
can occur inside the equipment. Always keep the cabinet closed to avoid condensation in-
side the cabinet and take into consideration the climate and humidity of the operating envi-
ronment. To reduce a condensation problem, run an inlet water temperature just above the
dew point.
• Ensure that the cooling water quality conforms to the specifications in 5.6 Cooling Water
Quality.
Figure 5–6 Cooling water connection

INSTALLATION
5.6 Cooling Water Quality

The quality of the cooling water for all of the systems must have the following purity:
Characteristic Specification
pH between 7.0 and 9.0
chloride content [CI] ≤ 20 ppm
nitrate content [NO3] ≤ 10 ppm
sulphate content [SO4] ≤ 100 ppm
total solids content ≤ 250 ppm
total hardness, as calcium carbonate [CaCO3] ≤ 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 Ωm 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.
When there is a risk of water freezing, add an anti-freeze agent, type Mo-
nopropyleneglycol (MPG) without additives, to the cooling water. Use on-
ly Monopropyleneglycol as other anti-freeze agents may influence the
conductivity of the cooling water, and may also lead to deposits in the
cooling system. The rate of mixture shall be adequate to avoid freezing,
but shall not exceed 30% Monopropyleneglycol / 70% water (correspond-
ing to anti-freeze protection down to –14°C/7°F).
To avoid condensation problems in the cooling system, keep the inlet

water temperature above the dew point.

INSTALLATION
5.7 External Interface Signals

• An external control system can control the Sinac.
• Connect the external interface signals, input and output, to the Sinac according to the con-
nection diagrams and time chart, attached in volume 2, Technical Description. CCM=Cus-
tomer Communication Module.
• On the Sinac operating panel, set the control source mode to REMOTE.
Figure 5–7 CCM connection located inside the Sinac
5.8 System Grounding Principles

5.8.1 High Frequency Induction Equipment and Grounding
The purpose of this section is to describe grounding and potential electrical noise problems in
the HF induction equipment installations. Local regulations regarding grounding usually con-
sider low frequency (50/60 Hz) installations only. When installing HF equipment it is necessary
to consider additional grounding to prevent electric noise which will be generated by the nature
of such installations. Make sure that the HF cables are laid out to minimize the electromagnetic
field. Keep the HF cables close together and keep distance between the HF cables and control
cables.
Special care must be taken when installing distributed induction installations. Distributed in-
duction installations are stationary installations comprising of an Induction heater (Converter)

INSTALLATION
with several components interconnected by power cables and / or signal cables. Components
can be heating stations, ECU, pump stations, and other peripherals.
Types of grounding used in installations:

• Protective conductor (identification PE): connected for safety to a single connection on the
equipment grounding terminal. Marked PE or colored green/yellow. Part of the equipotential
bonding circuit, with the chassis or mechanical structure to form the complete circuit.
• Functional bonding conductor: An electrical circuit with a conductor connected to the equi-
potential bonding circuit. Connection to the PE terminal. Used to prevent faults.
• Grounding for HF equipment: Additional grounding may be necessary to prevent problems
from the HF output magnetic field that may induce currents causing disturbing ground cur-
rents or generate noise on signal cables.
Protective earth areas for grounding are labelled either PE or .
All grounding must be to Main Ground including connecting components.

DO NOT ground components in series.
5.8.2 Installation Guidelines

Electrical Installations
Make sure that all power supply cables are grounded according to local regulations. This is
valid for both external power supply cables and internal power distribution cables.
High Frequency Grounding

1. Signal cables must be routed as far as possible from power cables, like high frequency in-
duction power cables and motor power cables. Power cables and signal cables should be
laid in separate conduits or tied to separate sides of a cable chain or conduit.
2. An equalizing ground connection between induction system components and the frequency
converter (the noise source) must be laid. This grounding must be routed the shortest pos-
sible way. Cable ducts etc. can be good ground conductors.
3. Signal cables and ground wires between components in an installation should be laid to
prevent formation of ground loops as far as possible.
4. All cable screens are to be connected to ground in both ends. The grounding must be done
inside enclosures close to the cable entry. Cable screen clamps, clamping the cable screen
directly to a ground bar or cable glands with ground fingers, should be used.
5. All enclosures connected with signal cable(s) must also be connected by a ground wire con-
necting the ground bars in both enclosures. Signal cables and the ground wire should be
laid as closely together as possible and preferably tied together with cable ties. Ferrite
cores may be mounted on the signal cables to force noise over to the parallel ground wire.

INSTALLATION
6. Sensors, actuators, junction boxes, and cabinets with grounding possibility must be
grounded locally, to framework etc., directly or with a short ground connector. All frame-
works must be connected together. Two frames connected electrically should be connected
with a ground cable running together with the signal cables. Also surrounding components
which may be affected by stray fields from the inductor should be grounded to the heating
station.
The equalizing ground connection mentioned in point 2 and the ground

wire mentioned in point 5 can be combined if signal cable routing is short
and direct.
The specific voltage equalizing wire from the induction coil to the fre-
quency converter is not regarded as the wire mentioned in point 2. Coil
voltage equalizing wires should be routed together with the high fre-
quency power cables.
A green/yellow ground cable in unscreened signal cables and power ca-

bles must be connected to the ground bar in both ends. Only one cable
shoe is allowed for each connection point. This ground cable might re-
place the equalizing ground connection mentioned in point 2.
Connecting Cables from a 3rd Party Supplier

Make sure all documentation regarding the connection of any 3rd Party system like field
busses etc. is available and complied with. If no specific requirements are mentioned, then ca-
bles should be connected according to high frequency grounding guidelines as mentioned
above.

CONNECTING AND USING THE COIL
6 CONNECTING AND USING THE COIL

1. Always switch off and/or disconnect the main power supply before connecting / disconnect-
ing the coil.
2. Connect the coil. Make a good electrical contact between the coil and the output terminals
— be sure that the contact surfaces on both the coil and the output terminals are free of dirt,
oil and oxides. If necessary, clean the surfaces with fine emery paper.
3. Ensure that the O-rings for the cooling water seals are free of any dirt or damage.
4. When fitting the coil to the output terminals, make sure the parallel gap between the output
terminals and the coil terminals are maintained. A misaligned coil terminal may lead to a
short circuit.
5. Use only brass termination nuts to fasten the coil. DO NOT use nuts of any other material.
Torque or tighten the nuts / terminals securely to prevent water leakage or overheating.
• 9 Nm for HHT 125A
• 14 Nm for HHT 125S, 240S, 400B and 400S
• 16 Nm for HHT 1200
• or tighten to ensure a good electrical contact
6. Once the flow of cooling water has been opened, hold the HHT so that the coil points up-
wards. This prevents air bubbles from being trapped inside the transformer, which can
cause local overheating of areas that are not in contact with the cooling water. For fixed coil
installations, let the water flow 30-60 sec before running output power.
7. Prevent short circuits in the coil during operation by avoiding contact between the coil and
the workpiece. If contact is difficult to avoid, coat the coil with an aluminium oxide coating
(avoid oxide on the contact surface). This will reduce the risk of short circuits. Some but not
all coils supplied by EFD Induction a.s are already coated with an aluminium oxide.
8. Check the torque of the nuts on the coil termination with a torque wrench every 14 days or
more often if necessary. Temperature cycling and mechanical movement are factors that
could cause the nuts to loosen. If the unit is started after a period of e.g. storage, also check
the torque of the nuts.
The hand held transformer is a vulnerable part of the equipment and

therefore must be handled with care.
TEST RUN: When changing the induction coil or heating new materials,
run tests to check the equipment settings.

SYSTEM DESCRIPTION
7 SYSTEM DESCRIPTION
The Sinac Induction heating system consists of three major units: The frequency converter
FC, the output unit and the induction coil.
A Twin/Dual system consists of two output units and induction coils.
The output frequency is given by the resonance circuit, i.e., the coil inductance and the reso-
nance capacitor bank.
The control system adjusts the inverter switching frequency to match the resonance frequency.
This ensures that maximum performance from the equipment is always achieved.
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 work-
pieces and increases in temperature, among other factors. The following table gives nominal
power matching current ratio and matching resistance ratio. The ratio is calculated from the
maximum output current.
Equipment Maximum current Matching current Matching resistance

(Display) ratio ratio
6/10 SM
135 A 9.5:1 90:1
6/10 SM Twin
12/18 SM
135 A 4.8:1 23:1
12/18 SM Twin
18/25 SM
135 A 3.2:1 10:1
18/25 SM Twin
25/40 SM
175 A 2.8:1 7.8:1
25/40 SM Twin
50/80 SM 350 A 2.8:1 7.8:1
7.1 Frequency Converter

The frequency converter is indirectly water-cooled, and has a diode rectifier and full-bridge
IGBT transistor inverter.
The main supply is fed from the mains input cable through the bottom of the cabinet and is
connected to a manually operated main isolating switch for units not a part of a system.
Operating this switch will connect the main power, and at the same time, turn on the auxiliary
voltage.
From the main isolating switch, the voltage is connected to high-speed fuses leading to the
main contactor and then to the rectifier diodes of the converter module.
The electronics power supply is taken from the mains input and fed through a

SYSTEM DESCRIPTION
3 x 500/220 V transformer to the SMPS cards. The SMPS and POWS are in the main elec-
tronic rack supply control and monitoring circuits.
The main voltage is rectified by a 6-pulse diode rectifier and fed to the IGBT inverter module.
The cooling water inlet and outlet are situated at the bottom of the cabinet. A water filter is in-
stalled outside the cabinet for easy access. Water flow and temperature are both monitored.
7.1.1 Control Panel

The control panel consists of the operating panel (OPN) located on the cabinet outside. The
FC always has one control panel, even when configured as Twin or Dual.
Switches and Indicators

The switches and indicators on the lower part of the OPN allow the operator to access the
main control of the FC.
Operating Panel
The display and keyboard, on the upper part of the OPN, provide a number of different menus
and functions to the operator.
The ELR (Electronic Rack)

The ELR is installed inside the cabinet and consists of the card holder, MECC and electronic
cards.
7.2 Output Current Limitations

The output current of IGBT inverters is adjustable between minimum and maximum levels.
The minimum level depends on the actual load. The typical power regulation range is 2-100%
and current range is 8-100%. The maximum level depends on the output frequency. At low fre-
quencies, 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 dependent 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 to zero. This means
that a small output current will run through the induction coil. The reason
for this is that the frequency converter's regulation system needs some
power feedback to function.

SYSTEM DESCRIPTION
7.3 Output Unit

The output unit is a series compensation unit with a water-cooled capacitor bank (CAP) that
produces the necessary reactive power needed in the load circuit. The output unit also con-
sists of an output transformer that transforms the output current/voltage to a current/voltage fit
for the coil. A standard FC output unit consists of a capacitor bank and an output transformer
type Hand Held Transformer (HHT) connected directly to the coil.
Other FCs may have additional capacitors installed in a special cabinet, such as a Heating
Station (HS). The output transformer is then located in either the FC cabinet or the HS cabinet.
7.3.1 Hand Held Transformer (HHT)

The HHT is connected to the output unit through water-cooled flexible cables with a length of 5
m, optionally 10 m. The HHT in some cases is equipped with holding brackets, or it might be
fixed to a machine or a specially made fixture.
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, for different
types of applications like heat treatment, forging, brazing, etc. The coil output voltage depends
on the output power and the length and design of the coil. The correct choice regarding type of
HHT for every specific application can only be done once all information regarding the applica-
tion in question is available.
If a very large induction coil or a multi-turn coil is needed for the application, a HHT with a dif-
ferent ratio or other type of output transformer might have to be used.
7.4 Distribution Network Requirements

This equipment complies with IEC 61000–3–12 provided that the short-circuit power Sѕс is
greater than or equal to 16.45 MVA at the interface point between the user´s supply and the
public system. It is the responsibility of the installer or user of the equipment to ensure, by con-
sultation with the distribution network operator if necessary, that the equipment is connected
only to a supply with a short-circuit power Sѕс greater than or equal to 16.45 MVA.
Sѕс = Sequ x Rsce Example 1:

Sequ = √3 Ui x Iequ Sequ for 25/40 = √3 x 400V x 67A ~ 47 kVA
Rsce ≥ 350 Sѕс for 25/40 = 47 kVA x 350 = 16.45 MVA
7.5 Interface and External Control

The Sinac frequency converter has several optional interface possibilities. These can be used
to control and/or monitor the Sinac. Typically, a Sinac can be connected to an EFD Induction
supplied External Control Unit (ECU), a manufacturing line control PLC or a simple control
gear in a remote desk. The optional interfaces are implemented as a range of Customer Com-
munication Modules (CCM).

SYSTEM DESCRIPTION
Different types of CCMs can be combined to achieve the desired configuration of external in-
terfaces. It is possible to have both a hardwired interface and a field bus interface, but only
one of them will be allowed to give commands. Both interfaces can provide status and monitor-
ing information.
The Sinac can be delivered as a Twin unit. This means that there are two independent outputs
to be controlled and monitored. Depending on the selected CCM’s nature, the Twin output side
may need separate CCMs. These modules have the same CCM number, but with a ‘T’ after
the number. Note that Emergency stop CCMs and fieldbus CCMs can operate both output
sides, and therefore, do not have a ‘T’ version.
7.6 Performance Level

The performance level (PL) is a value used to define the ability of the safety-related parts of
control systems (SRP/CS) to perform safety functions under foreseeable conditions. Addition-
ally, the required performance level (PLr) is used to achieve the required risk reduction for
each safety function. Therefore, the performance level (PL) of safety-related parts of a control
system (SRP/CS) must be greater than or equal to the required performance level (PLr). The
actual performance level (PL) for the Sinac can be found in the technical specification table in
volume 2, Technical Description.
Performance Level (PL) Probability of Dangerous Failure per Hour (PFHD) 1/h
a ≥10-5 and <10-4
b ≥3 x 10-6 and <10-5
c ≥10-6 and <3 x 10-6
d ≥10-7 and <10-6
e ≥10-8 and <10-7
The safety-related parts of the Sinac are regarded as a subsystem to a customer’s larger
safety system. The performance level (PL) for the customer’s complete system must be re-
viewed by the customer to meet the required performance level (PLr).

OPERATING THE CONTROL PANEL
8 OPERATING THE CONTROL PANEL

The Sinac is equipped with a control panel. The control panel consists of an operating panel
and an electronics rack. The OPN 1065 Operating Panel is located on the outside of the cabi-
net and has a display, keyboard, operating switches and indicators. The ELR with electronic
cards is located inside the cabinet.
8.1 Operating Panel (OPN)

The display and keyboard together form the Sinac’s Man-Machine Interface (MMI). A number
of different menus and functions are available to the operator.
8.1.1 Display and Keyboard

The top row of the display screen is divided into three areas. The left area displays the menu
identifier number, the center area displays the menu name, and the right area indicates the re-
turning key. When the PIN code is active, a “padlock” symbol is displayed in the upper right
corner.
The center part of the display screen shows the contents of the selected menu. A bar graph of
relevant internal analog signals or operator selectable values can also be shown on the dis-
play. Each menu shown on the display contains explanatory text indicating what options and
information are available. The bottom line or footer shows messages for operations and
alarms.
Figure 8–1 Display screen layout
1) Top area. 2) Center area. 3) Bottom area.

Figure 8–2 Display and Keyboard.
Key Function
Ten function keys, F0-F9 For selecting different functions. F9: For returning to the previous
menu.
Number keys, 0-9 For typing numbers.
Enter key, ↵ For entering typed numbers.
Arrow keys, ⇑ ⇓ To adjust the output reference and for use where a function comprises
more than one line.
Clear key, // Clears typed numbers if the enter key has not yet been pressed.

8.1.2 Operating Switches and Indicators

The lower part of the operating panel provides operating switches and indicators used during
local operation.
Figure 8–3 Switches and Indicators
Picto-
Key Type Function
gram
Auxiliary voltage Indicates that the voltage for the auxiliary circuits are
Indicator
on.
Ready Indicator Indicates that the system is ready for use.
Indicates that some fault condition is present. This will
Failure Indicator block the power on function until the alarm system is
reset.
Local / Indicates if the unit is to be controlled from the operating
Indicator
Remote panel or via the external control system.
Power on Switch Switches the output power on.
Power off Switch Switches the output power off.

Resets the alarm system when a fault condition is no
Reset Switch
longer present.
Indicates that OPN presents values and control for out-
Output 1 Indicator
put 1. The single version always has Output 1.
Output 2
Indicates that OPN presents values and control for Out-
(Twin/Dual unit Indicator
put 2.
only)
Control Select
Select the output that is controlled by the operating pan-
(Twin/Dual unit Switch
el and is displayed.
only)
Allows operator to select between Local or Remote
Local/Remote Switch
modes of operation.

OPERATION
9 OPERATION
PACEMAKERS: Anyone using a pacemaker may be at risk when in the

vicinity of the induction heater's coil section. There is a risk that the elec-
tromagnetic fields produced by the induction heating unit may interfere
with the performance of the pacemaker.
CAUTION! RISK OF BURNS: Avoid wearing materials that conduct

electricity close to the body. Also, be aware of protective shoes with
metal tips. Energize the coil only when it is in the vicinity of the
workpiece.
WARNING! To avoid personal injury, do not open the equipment's

covers or panels. Under any circumstances, do not operate the
equipment without the covers and panels properly installed.
9.1 Before Starting

For first time start, connect the equipment according to Section 5 INSTALLATION. If the equip-
ment will be started after a long period of disuse then routine / periodic maintenance and
cleaning must be performed according to Section12 MAINTENANCE.
9.2 Start
If the Sinac has a cabinet-installed main-power switch, it is located on the front of the cabinet.
Otherwise, there will be an external, wall-mounted main-power switch that may service more
than one induction heater.
Figure 9–1 The main power switch is mounted on the Sinac cabinet
1. Turn on the Sinac´s main switch.

OPERATION
2. The following lamps should light:

• AUXILIARY VOLTAGE lamp on the operating panel
• READY or FAILURE lamp
• LOCAL or REMOTE lamp
• OUTPUT 1 or OUTPUT 2 lamp
The display on the operating panel briefly shows a startup screen followed by the Display
Values Menu. This menu provides normal operational values during the heating process.
9.2.1 Programming the MMI

If the MMI is already programmed and no editing is needed, go to Section 9.2.2 Output Power
Control. Otherwise, return to the MMI's main menu by pressing F9 and perform the necessary
programming/editing.
1. Choose Control Functions (Activate Menu); there are several types of control
functions
• Sequence
• Timer
• Water Auto Shut-off
• Energy Supervision
• PIN Code
• Language
• Extended Operating Range — EOR
The sequence and timer functions are mutually exclusive. For further information about the
control functions, refer to Sections 9.2.2 Output Power Control or 10.1 Control Function
• Go to the Activate Menu (F0 in the Main Menu).
• Activate the desired control functions by pressing the keys in front of the various options
(sequence and timer are mutually exclusive functions).
• Return to the Main Menu (press F9).

OPERATION
2. Choose Mode of Operation (Setpoint Menu)
There are two modes of operation, mutually exclusive functions: AC current and DC power.
The selected mode of operation regulates the output power determined by a given setpoint.
For further information about modes of operation and the relevant setpoint, refer to Sections
9.2.2 Output Power Control and 10.1 Control Function
Temperature operation is optional, additional equipment required.

• Go to the Setpoint Menu (F1 in the Main Menu).
• Choose the mode of operation.
• Return to the Main Menu (press F9).
9.2.2 Output Power Control

Output power can be operated from different control sources.
1. Control from Local Operating Panel
The LOCAL/REMOTE mode selector must be set at LOCAL when the converter power ON/
OFF is operated from the operating panel only. Turn the output power on and off with the
POWER ON/POWER OFF buttons. The output power level will come from the selected set-
point source, unless the sequence function is activated. Possible settings for setpoint
source: LOC, EXT or DEFAULT. Refer to 11.4 Setpoint Menu (menu 3).
If the setpoint source is set at either LOC or DEFAULT, then the output power level can be
set with the ‘UP’ and ‘DOWN’ arrows on the operating panel. If the setpoint source is set at
EXT the setpoint comes from the Remote Interface. When the timer function is active, the
output power will be on until either a preset time has elapsed or the POWER OFF button is
pressed.
CAUTION! When the mode selector is set at LOCAL and the set-
point source is EXT then the output power can NOT be turned on/
off from the Remote Interface, only from the operating panel.
If the sequence function is activated, the function will start each time the POWER ON button
is pressed. Set the output power level in the sequence program (refer to 11.6 Sequence
Menu (menu 4)). To interrupt the function, press the POWER OFF button.

OPERATION
2. Control from the HHT (Optional)
Control of the output power ON/OFF with the button on the HHT handle is independent of
the LOCAL/REMOTE switch position. Turn the output power on by continually pressing the
button.
When the timer/sequence is activated in the Activate menu, it runs (with output power on)
as long as the button on the HHT is depressed and until the selected time has expired. The
HHT on/off button must be released before a new timer/sequence can be started. Optional
latching of output power on can be combined with a specific HHT control handle pre-in-
stalled by EFD Induction.
If the HHT in use has a pistol-grip (‘Hand Grip’), then the handle is equipped with a trigger
type push button with an LCD. The LCD indicates output power on. When the push button
is activated, the output power will be switched on. If setpoint source is set at HHT or DE-
FAULT, pressing the trigger switch further through its travel will increase the output level.
Possible settings for setpoint source: LOC, EXT, HHT or DEFAULT. Do not select HHT or
DEFAULT if the HHT ‘hand grip’ only has ON/OFF switching.

OPERATION
3. Control from Remote Interface
Different types of ECUs (External Control Units) (EFD Induction product or customer’s) can
be used to operate the Sinac. The start-up sequence will vary depending on the control sys-
tem used. Make sure that the LOCAL/REMOTE mode selector is set at REMOTE. The out-
put power level will come from the selected setpoint source, unless the sequence function
is activated. Possible settings for setpoint source: LOC, EXT or DEFAULT (for details, see
Section11.4 Setpoint Menu (menu 3)).
If setpoint source is set at LOC, then the output power level can be set with the UP and
DOWN arrows on the operating panel. Also the power ON cannot be used but the power
OFF can on the operating panel. If setpoint source is set to EXT, the output power level is
set from the remote interface.
DEFAULT: Setpoint source comes from the power command source.
Precision of “Power On Command”: It is important for the heating proc-

ess repeatability that the digital input “Power On Command” is repro-
duced accurately for each workpiece to be heated. A variance in time
in this signal will affect the heat produced accordingly. As a conse-
quence of this, the control output that gives this signal must not be
based on a relay, as a relay may produce “bouncing”. Transistor based
outputs are therefore preferred.
a. Foot Controller/ Foot Switch
The unit can be equipped with a foot controller or a foot switch. The LOCAL/ REMOTE
mode selector must be set to REMOTE when the system is operated from a foot con-
troller/switch. Turn on the output power by operating the pedal. A foot switch only gives
power on/off. When using a foot controller, increase the output power level by pressing
the pedal gradually (0-100% control range). Possible settings for setpoint source : EXT
or DEFAULT for foot controller / LOC for foot switch.
9.2.3 Alarms Indication

If any alarm is activated, an alarm message will pop up in the footer area of the display and the
failure lamp will light. If an alarm is activated, find the cause of the alarm and remove it (refer
to Section 13.1 Alarm Messages). Press the RESET button to reset the FAILURE lamp.
Do not remove the equipment's covers or panels. Refer trouble-shooting

to qualified personnel.

OPERATION
9.3 Output Power

For maximum output power for continuous use and intermittent duty, see volume 2 Technical
Description table.
The load value (load impedance) is given by the coil construction and the shape and material
of the workpiece. For operating at maximum power the load must be within a certain range.
This range decreases with increasing power and maximum intermittent power is obtainable
only within a limited range of load impedance. The output power can be regulated by using the
following parameters.
AC current
Using the current to regulate the output power is recommended for heating processes with
varying impedance as a constant current produces constant induction. Typical application:
hardening.
DC power
DC power regulation is recommended for heating processes where the load is constant (con-
stant impedance) or in general where heat absorption varies as a function of the heating tem-
perature. This mode of operation is generally chosen when the equipment is used in a
production line.
Temperature
Temperature mode can be used in special applications where a temperature sensor is installed
at the workpiece. This also requires an optional temperature input connector.
In local operation, the setpoint can be either entered as a percent value in a sequence pro-
gram or adjusted by using the “up” and “down” arrows.
As long as a POWER ON signal is given, the output power will never be

zero, although the reference setpoint may be set to zero. There will be a
small current in the coil because the Sinac´s regulation system needs
some current feedback to function.
9.4 Distance to Workpiece

The efficiency of the coil decreases as the distance to the workpiece increases. The best re-
sults are obtained where the distance between coil and workpiece is
1-3 mm. Practical reasons, such as the shape of the workpiece, may require a larger air gap
between the coil and the workpiece, although this may reduce efficiency.

OPERATION
9.5 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.
2. Turn off the main switch.
3. When the converter is turned off, a built-in magnetic valve (if installed) closes the water flow
to the converter. Any external inlet/outlet water valves should be closed when the equip-
ment is left unsupervised for an extended period of time.
Do not leave the Sinac with voltage on and no water flow. This will re-
duce the lifetime of components due to the rise of internal temperatures.
If the equipment is to be kept or transported in areas where there is a risk

of low temperatures and damage from freezing, then drain the cooling
system. Set the MAIN switch to the ON position and deactivate the “auto
water shut off” system before supplying compressed air to the water inlet
tailpiece (refer to Section10 OPERATIONAL INFORMATION). Keep the
outlet tailpiece open— Do not use a snap-action valve.
9.6 Emergency Stop/External Stop Command

If an Emergency Stop is activated, the alarm message “Emergency Stop” appears on the foot-
er display. The power output of the converter is switched off and all power on functions of the
converter are blocked. Alternatively, the “External Stop Command” appears on the footer dis-
play, when a main supply contactor is not installed inside the converter.
9.7 Restart after Emergency Stop/External Stop Command

To restart after an Emergency Stop/External Stop Command, first find the cause of the stop. If
a reset is authorized, release the stop signal and press the “RESET” button on the operating
panel. See section 8.1.2 Operating Switches and Indicators. Follow the normal start proce-
dure. Refer to Section 9.2 Start.
DANGER WHEN RESTARTING: To avoid repeating a dangerous sit-

uation, do not restart the equipment before finding the reason for
activation of the Emergency stop/external stop command and cor-
recting the cause.

OPERATIONAL INFORMATION
10 OPERATIONAL INFORMATION
The operating panel buttons, menus and functions present one power output at a time. In Twin
or Dual configurations, the output presented on the OPN is selected by pressing the Control
Select button (lower right button on the OPN switch and indicator panel –“Control select”).
During normal operation, select one of the MMI information screens:

• Display Values (menu 24)
• Display All Values (menu 19)
• Display Timer/Sequence (menu 23)
• Twin Display Values (menu 36) (Twin/Dual units only)
Refer to menus 24, 19, 23 and 36. These menus provide continuous information about current
operating conditions, e.g., output power, voltages, and current values. The output frequency is
displayed in the F7 Status information, and in the “Display Values” and “Twin Display Values”
menus.
Regardless of which menu is selected, each screen contains a footer displaying alarms, indi-
cations/limitations and operational messages. The various messages are described in Section
10.3 Footer Messages.
10.1 Control Function

Sequence
The sequence function enables the operator to run specific heating sequences. Eight different
sequence programs can be entered in the Sequence Menu (menu 4). If the sequence function
is activated, the sequence (program no.) selected in the Sequence Menu will start each time a
POWER ON signal is given.
In REMOTE mode, the sequence program to be started is selected via

the external interface.
Timer
The timer function enables the operator to run the unit at a specific time interval. The duration
of the interval is selected in the Timer Menu (menu 7). If the timer function is activated, the time
interval starts each time a POWER ON signal is given. This means that the output power is on
from the moment a POWER ON signal is given until the time interval has elapsed or POWER
ON signal is removed.

Water Auto Shut-off

Activating the "Water auto shut-off" function automatically closes the water flow 20 seconds
after the output power is turned off. This cuts down on water consumption. To turn the power
on again, press the POWER ON button and hold it for a minimum of 1.6 seconds until the out-
put power comes on. This time delay makes sure that the water is flowing before any heat de-
velops. This function is disabled on units without a water solenoid control valve.
When the cooling water temperature is low at the same time as the ambi-
ent temperature is high, activate the "Water auto shut-off" function in the
Activate Menu to avoid condensation on pipes, etc., inside the unit.
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 val-
ue. The energy consumption of the following runs (of the same program no.) will be compared
with the stored value. If the current value is within the allowed deviation, “OK” or a is shown
in the Display Timer / Sequence Menu. If it is not within the allowed deviation, “LOW/HIGH” or
a is shown.
The energy supervision function is activated/deactivated in the Activate Menu.
PIN Code
The PIN code function provides a security option for system programming. The function is de-
scribed in Section 11.2 PIN Code Menu (menu 26).
Select Ext. Interface (optional)

This function is only available on units specially equipped with both hardwired external con-
nection and a fieldbus connection. Setting this function at "Hardwired" causes all external con-
trol input to the unit to come from the hardwired external interface. Setting it at "Fieldbus 1"
causes all external control input to the unit to come from the fieldbus connection. However,
both external connections will provide information regardless of the selected function.
10.2 Power on Command

When a hardwired control is used, it is important for the heating process repeatability that the
digital input "Power on command" is reproduced accurately for each workpiece to be heated.
A variance in time in this signal will affect the heat produced accordingly. As a consequence of
this, the control output that gives this signal must not be based on relay, as the signal may
have “bouncing”. Transistor-based outputs are therefore preferred.

10.3 Footer Messages

Each screen shown on the display contains a footer field where the following information is dis-
played (with priority as indicated):
1. Alarm messages.
2. Indications/limitations when the power is on.
3. Messages during normal operation.
Alarm Messages
Remove the alarm messages by eliminating the cause of the alarm and pressing the RESET
button on the operating panel. Refer to Section 13.1 Alarm Messages for the table of alarm
messages with probable causes and corrective actions.
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 or capacitor has reached
a preset maximum level for the current load and frequency level, preventing further in-
creases in output power.
• High Frequency Current Limit: The output current (going through the transistors) has
reached a preset maximum level for the current load and frequency level, preventing further
increases in output power.
• Maximum AC Current Limit: The output current has reached a preset maximum level, pre-
venting further increases in output power.
• Maximum DC Power Limit: The DC power has reached a preset maximum level, preventing
further increases in output power.
• Output Limited: Output limited by other limitations of the inverter.
• Output Reduced by EOR: The extended operating range (EOR) function has reduced the
output to a secure level for the current cooling water flow and temperature, preventing fur-
ther increases in output power.
Messages During Normal Operation

• Ready: The unit is ready for operation. Operate a POWER ON device.
• Power On: The output power is turned on.
• DC Power: DC power is the current mode of operation.
• AC Current: AC current is the current mode of operation.
• Main Contactor Off: Main contactor is not successfully connected.
• Timer Active: The timer function is active.
• Sequence Active: The sequence function is active.

• Extended Operating Range Activated: The Extended operating range function has been ac-
tivated, 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 nor-
mal operation’.
• Water Tank Level Low Warning: A connected sensor in an optional cooling water tank has
detected low level. Refill the water tank and check for leaks in the water cooling system.
This message flashes, alternating with the rest of the ‘Messages during normal operation’.

MENUS
11 MENUS
When the Sinac is turned on, the system briefly displays the EFD Induction logo screen with
the software version and then automatically enters menu 24, "Display Values". Press F9 to re-
turn to the Main Menu. Continuing to press F9 will return to the EFD Induction logo screen.
Figure 11–1 Menu Navigational Chart
The push buttons F0 – F8 on the Keyboard panel are used to maneuver and make selections
in the menus. The same button can have different functions in different menus. F9 is always
used to return to the parent menu. The menus are organized hierarchically (parent–child log-
ic). The actual menu number is displayed in the upper-left corner of the display panel.
The Main Menu consists of the following sub-menus:

F0 Activate menu {menu 2}
F1 Setpoint menu {menu 3}
F2 Timer menu {menu 7}
F3 Sequence / Energy menu {menu 4}
F4 Display Values {menu 24}
F5 Display Timer / Sequence {menu 23}
F6 Twin Display Values {menu 36} (Visible only in Twin units)
F7 Status info. {menu 29}

MENUS
If the Timer or Sequence functions are enabled, menu 23, “Display Timer/Sequence” is en-
tered instead. In Twin units, menu 36, “Twin Display Values” can be selected to view informa-
tion of both outputs. One of these menus is selected as the opening menu to facilitate
operation once all settings have been entered.
The operator does not need to use the keyboard to obtain information on the operational val-
ues during the heating process.
11.1 Activate Menu (menu 2)

This menu enables the operator to choose control functions. Press the key in front of the re-
quired option to make a selection.
"Sequence" and "Timer" are mutually exclusive functions. Press F4 to call up the PIN Code
Menu.
If a change of language is needed press F5 to shift the menu through the possible languages.
F0 Sequence <ACTIVE/OFF>
F1 Timer <ACTIVE/OFF>
F2 Water auto shut-off <ACTIVE/OFF>
F3 Energy supervision <ACTIVE/OFF>
F4 PIN code <ACTIVE/OFF>
F5 Language Change to next available language
F6 Extended Operating Range <ACTIVE/OFF>
F7 Change IP-Address {menu 39}
F81 Select Ext.interface <Hardwired / Fieldbus 1>
Return to the Main Menu by pressing F9.
11.2 PIN Code Menu (menu 26)

This menu provides a security option for the system through the entry of a Personal Identifica-
tion Number (PIN). The PIN Code Menu will automatically display when the operator tries to
enable/disable the PIN code function in menu 2 (Activate Menu). This ensures that only au-
thorized personnel can enable/disable this function. The PIN Code Menu is also called up au-
tomatically if the operator tries to change converter settings when the PIN code function is set
at ACTIVE. This prevents unauthorized personnel from reprogramming functions/settings in
the menus.
Once the PIN code is entered, the operator can change any settings without re-entering the
PIN code each time. After 5 minutes of inactivity on the keyboard, the PIN code protection is
reactivated. A “padlock” symbol, in the upper-right corner of the display, indicates that the PIN
code protection is active.
1. Only visible if the unit is equipped with both a hardwired and a fieldbus external interface.

MENUS
When the PIN code is entered (and accepted), the program returns to the previous menu.
Give PIN code <0-9999>
F0 Change PIN code {new menu 27}
The PIN Code Menu also contains a "Change PIN code" sub-menu. Press F0 to call up this
menu. Return to the previous menu by pressing F9.
Default PIN Code

The default PIN code on a new converter is the number 0 and can be changed in the Change
PIN Code Menu.
11.3 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>
Give new PIN code <0-9999>
Retype new PIN code <0-9999>
Return to the previous menu by pressing F9.
11.4 Setpoint Menu (menu 3)

This menu is used to select the mode of operation (type of regulation). Only one of the first
three modes in the list can be activated at a time (mutually exclusive functions). In addition,
this menu contains a function for selecting the setpoint source and signal type to / from the ex-
ternal control.
F0 AC Current <ACTIVE/OFF>
F1 DC Power <ACTIVE/OFF>
F2 Temperature <ACTIVE/OFF>
F3 Setpoint source <LOC/EXT/HHT/DEFAULT>
F6 Ext. signal select <DC power/AC current/DC voltage/ Frequency/
Temperature>
F7 Ext. setpoint signal type <0-10V/0-20mA/4-20mA >
F8 Ext. feedback signal type <0-10V/0-20mA/4-20mA >
Setpoint source
The options given in function F3 "Setpoint source" have the following definitions:

MENUS
LOC Setpoint from the control panel “up” and “down” arrows.
EXT Setpoint from an external device.
HHT Setpoint from HHT setpoint control.
DEFAULT Setpoint from the source where the power on command is detected.
If HHT handle is not equipped with a power control device make sure not to select HHT as Set-
point source as this will result in zero setpoint value.
11.5 Timer Menu (menu 7)

This menu enables the operator to program the timer.
F0 Time Unit <0.1 s/1 s/0.1 m/1 m/0.1 h>
Time <0-9999>
Select the time unit by pressing the F0 key. Use the down arrow key ⇓ to go to the "Time" line.
Enter the number of seconds (s) / minutes (m) / hours (h) using the number keys followed by
the enter-key ↵. Return to the Main Menu by pressing F9.
11.6 Sequence Menu (menu 4)

This menu enables operators to set up eight different programs, each composed of ten differ-
ent segments. Type, time unit, time and target setpoint must be defined for each segment.
F0 Program no <0-7>
F1 Segment no <0-9>
F2 Type <Step/Ramp>
F3 Time unit <0.1 s/1 s/0.1 m/1 m/0.1 h>
Time <0-999>
Target setpoint <0-100%>2<0–250°C3
F4 Energy menu {menu 8}
F5 Event output menu {menu 30}
To select a program number, segment number, segment type and time unit, press the relevant
function key until the requested number/option is displayed. To set time and target setpoint,
use the arrow keys, type in the requested number and press the enter key. Return to the Main
Menu by pressing F9.
Segment type: The two segment types are STEP and RAMP. While a step runs at a steady lev-
el determined by the target setpoint, a ramp increases/decreases to the level determined by
the target setpoint from the setpoint level given in the previous segment. If a ramp is the first
segment in a sequence, it always starts at zero.
2. Corresponds to Power or Current

3. If Temperature mode of operation is selected, this entry is in either degrees Celsius or percent.

MENUS
Table 11–1 Example of Table for Registering Program Settings

Segment no. Segment type Segment duration Target setpoint
0
1
2
3
4
5
Example of a Sequence
Figure 11–2 Sequence A illustrates a heating sequence, while Table 11–2 Sequence A, Pro-
gram no. 2 shows the sequence parameters. The example in the Table shows how to program
this sequence.
Figure 11–2 Sequence A
Table 11–2 Sequence A, Program no. 2

Segment no. Segment type Segment duration Target setpoint
0 STEP 4 min. 80%
1 RAMP 5 min. 30%
2 STEP 4 min. 30%
3 RAMP 3 min. 0%
11.7 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

MENUS
program) and state an allowed energy deviation value (as a percentage) for comparison
against later sequences. The energy check result is shown on the last line.
F0 Program no <0-7>
F1 Segment no <0-9>
F2 Store total energy
Allowed energy deviation <0-100%>
Segment energy (kj)
Total energy (kj)
Stored total energy (kj)
Energy check result <LOW/OK/HIGH>
• To select the program and segment numbers, press F0 and F1, respectively, until the de-
sired number is displayed.
• To store the total energy value, press F2.
• To set the allowed energy deviation value, enter the desired value and press the enter key.
Energy Supervision
The purpose of the energy supervision function is to detect changes in the heating process
when running the sequence function.4 A change in the heating process is often caused by
changes in the coil position relative to the workpiece or changes in the workpiece itself (pre-
heating, changes in mass/shape). Fault situations such as short circuits in the coil can also
cause changes in the heating process.
To make use of the energy supervision function, do not run the converter in the DC power
mode. In the DC power mode, the converter itself compensates for any changes in the heating
process.
Total energy is the amount of energy used by the equipment during the last program run. This
value can be used as a reference by the energy supervision function for later runs. When used
as a reference, the allowed percentage deviation value (±) must be entered into the program
memory. Before using this energy supervision function, install the converter properly and es-
tablish a perfect sequence program.
In some cases when using the temperature mode of operation, it is preferred to disable the en-
ergy count below a certain temperature to minimize the influence on the total energy caused
by variance in the workpiece start temperature. Only EFD Induction personnel shall configure
this function.
4. To calculate the exact amount of energy transferred to the workpiece, subtract the losses in the inverter, output circuit and coil.

MENUS
11.8 Event Output Menu

In this menu, a specific event can be configured to trigger an output during a sequence pro-
gram run. Each of the eight sequence programs can be configured separately. Two types of
events can trigger the output: ‘Temperature reached’ or ‘Segment output’. They are mutually
exclusive for each program number. The menu is dynamic so that if no event is selected for
the current program number, only the three first lines in the menu are visible.
F0 Program no <0-7>
F1 Temperature reached <ACTIVE/OFF>
F2 Segment output <ACTIVE/OFF>
1. Temperature reached
Temperature reached can only be used in equipment fitted with temperature sensing equip-
ment and when running a sequence in temperature mode of operation. When Temperature
reached is activated, the following lines appear:
Temp. reached 1 level (C) < 0-250 >
Temp. reached 2 level (C) < 0-250 >
100% corresponds to: (C) < 250 >
The operator can set two Temperature reached levels at temperatures between 0 and the
temperature sensor´s maximum value (in this case 250 °C). When the temperature at the
sensor is above the set ‘Temp reached level,’ the corresponding Event output (1 or 2) is
high; otherwise, it is low. The Event outputs are available only when using a fieldbus as ex-
ternal interface.
2. Segment output
When Segment output is activated, the following lines appear:

F3 Segment no <0-9>
F4 Event output 1 <LOW/HIGH>
F5 Event output 2 <LOW/HIGH >
The ‘Segment output’ function makes it possible to specify the Event outputs levels (Low or
High) for each segment in a sequence program. The Event outputs are available only when
a fieldbus is used as an external interface. A typical use of the event outputs is to synchron-
ize an outside operation with a heating event.
11.9 Display Values (menu 24)

This menu provides information on normal operational values. It displays a continuous graphi-
cal 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. Return to the Main Menu by pressing F9.

MENUS
The Display Values Menu also contains a "Display All Values" sub-menu. Press F0 to call up
this menu.
11.10 Display All Values (menu 19)

This menu shows all normal operational values in the form of bar graphs. These values are
AC current, DC power, Temperature, DC voltage and DC current. The bar graph representing
the value selected as the mode of operation is marked with the setpoint value. Return to the
previous menu by pressing F9.
11.11 Display Timer/Sequence (menu 23)

This menu provides a continuous graphical presentation of the current sequence or timer func-
tion (time is given as a relative value). Only one of these functions is shown since they are mu-
tually exclusive. This menu also shows the bar graph representing the value selected as the
mode of operation (AC current or DC power). The setpoint is marked on the bar graph. If en-
ergy supervision is activated, a “smiley” will show whether the energy check result is OK or
not.
OK: LOW/HIGH:
11.12 Twin Display Values (menu 36) (Only Twin/Dual units)

This menu provides information on operational values of both outputs in Twin units. The menu
is split horizontally into two parts, with the upper part showing information related to output 1
and the lower part correspondingly to output 2. Each part displays a graphical presentation of
AC current and DC power, and indicates the setpoint and AC current frequency. A footer mes-
sage, of the same type found in the other menus, is located at the bottoms of both the upper
and lower parts. The output number is displayed to the right of each footer message.
11.13 Status Info. (menu 29)

This menu displays the following parameters.
• Water flow (dl/min)
• Water inlet temperature (°C)5
• Output current frequency (kHz)
• Active alarms: Up to 7
Return to the Main Menu by pressing F9
5. Optional: In some units the water temperature is measured.

MENUS
11.14 Ethernet IP Addr. (menu 39) (optional)

In this menu, when an Ethernet based optional module is installed, the IP address related in-
formation can be changed.
IP address: 0. 0. 0. 0.
Subnet mask: 0. 0. 0. 0.
Default gateway: 0. 0. 0. 0.
Return to the pervious menu by pressing F9.
Some Ethernet based protocols like Profinet and Ethercat use the input
from the external connected network and NOT from this menu.

MAINTENANCE
12 MAINTENANCE
This maintenance section includes all routine and periodic maintenance for the Sinac. It de-
scribes the maintenance that can be carried out by qualified personnel. See Section 2.2 Quali-
fied Personnel for defined skilled vs. instructed.
The section does not offer any information about modifications to the system or extensive re-
pair work that requires specialized knowledge by EFD Induction service technicians.
Table 12–1 Maintenance — Required Qualified Personnel

Maintenance Instructed Skilled
Daily Inspections
• Inspect hoses & cables X
• Inspect & clean contact surfaces on the HHT terminals & coils
14 Day Inspection
X
• Torque/tighten HHT nuts
• Cleaning outside cabinet
Semi-Annual Inspection
X
• Clean cooling water filter
Semi-Annual Inspection
• Disconnect mains supply voltage
• Inspect cable and connections
X
• Inspect cooling water seals
• Inspect & clean inside the cabinet
12.1 Cooling System

• Periodically perform an external visual check of the HHT terminals and the O-rings for the
cooling water seals. The objective is that they are free of any dirt and not damaged.

MAINTENANCE
• Make a good electrical contact between the coil and the output terminals — be sure that the
contact surfaces on both the coil and the output terminals are free of dirt and oxides. If nec-
essary, clean the surfaces with fine emery paper.
Figure 12–1 Cleaning contact surfaces of coil and HHT.
1) Contact surfaces.
• Refer to Figure 12–2 Inlet water filter. Periodically clean the inlet water filter . Unscrew the
hose tail for the water inlet, retract the filter and clean it with compressed air.
Figure 12–2 Inlet water filter.
12.1.1 Cleaning Additives

To clean / rinse the cooling system and pipes for removing residue/calcareous deposits EFD
Induction recommends a citric acid based additive. It is vital to use an additive that does not
harm rubber / plastic or metal parts.
Be careful to read the manufacturer’s instructions of dosage and procedure for the cleaning
process. After the cleaning process, be sure to flush the system thoroughly before starting
production.
Cleaning of the system, if necessary, should be performed annually or when needed.

MAINTENANCE
12.2 Safety Regulations
Before performing maintenance work that requires open or removed

doors / covers, switch off the main switch to the system and disconnect
the supply voltage.
The system must be checked for residual voltage before starting maintenance work. If the
doors / covers are removed, the system must never be left unattended.
DANGER! HIGH VOLTAGE: NEVER perform maintenance with the

doors / covers opened / removed and voltage still connected. The
unit must never be left unsupervised when the doors / covers are
opened / removed. Such conditions involve a risk to life and equip-
ment. Be sure there is no residual voltage in the system when the
doors / covers are opened / removed. The main switch discharges
internal voltages when in the OFF position.
ALSO, CHECK THAT THERE IS NO RESIDUAL VOLTAGE IN COILS

OR OUTPUT UNITS!
12.3 Daily Inspections

When the system is operated with normal usage, daily inspections outside the cabinet are re-
quired. Inspections can be performed by instructed qualified personnel.
• Inspection of the external hoses and cables for cracks and mechanical damage.
• Check the contact surfaces on the HHT terminals and coils for dirt and damage.
• Check for signs of high temperature. If necessary clean the contact surfaces.
If there is any damage to the hoses between the Sinac and the output transformer, then skilled
qualified personnel must remove the hose / cable and send it to the nearest EFD Induction
branch office.
SPECIAL EQUIPMENT: The HF power cables for the output transformer

are located inside water hoses. DO NOT cut these hoses!
12.4 Routine Maintenance

In the following sub-sections, the time intervals at which the maintenance work must be per-
formed are specified according to both the calendar and the number of hours of operation.
Perform maintenance work at whichever interval comes first.

MAINTENANCE
12.4.1 14 Days Inspection

(approximately 75 - 100 hours of operation)
(Can be performed by instructed qualified personnel.)

• Perform the check when the main switch is switched off and the supply voltage is
disconnected.
• Clean away dirt located on the HHT terminals and coils.
• Check for signs of high temperature. If necessary clean the contact surfaces.
• Use a torque wrench to torque the HHT nuts: 9 Nm for HHT 125A, 14 Nm for HHT 125S,
240S, 400B and 400S, and 16 Nm for HHT 1200.
• or tighten the nuts to ensure a good electrical contact
Cleaning
Do not flush the converter with a powerful water jet or use strong deter-
gents. Depending on the environment, clean the Sinac from time to time
of dust, emulsion spray, etc. Clean with a mild degreasing agent or
detergent.
12.4.2 Semi-Annual Inspections

(approximately 1000 hours of operation)
A. Clean the cooling water filter by the following procedure:

(Can be performed by instructed qualified personnel.)
1. Close the valves on the cooling water inlet first and then the outlet. The cooling water filter
is located at the input pipe for the cooling water. Figure 12–2 Inlet water filter.
2. Turn off the main switch and disconnect the supply voltage.
3. Unscrew the hose tail for the inlet water, retract the filter, clean it with compressed air and
then install it again. Figure 12–2 Inlet water filter.
4. Wipe away any water that has splashed out.
5. Open the valves on the cooling water outlet first and then slowly open the valve for the
water inlet.
6. Check whether there are any water leaks as the water pressure increases.
7. If the water filter is very dirty or if problems arise that prevent sufficient water flow, perform
this procedure more often.

MAINTENANCE
B. Inspect components, connections and maintenance inside the FC cabinet by the

following procedure:
(Must be performed by skilled qualified personnel.)
1. Turn off the main switch and disconnect the supply voltage.
2. Open / remove the doors / covers for the cabinet.
3. Inspect all components thoroughly for damage, wear, signs of aging and look for indications
that the system is running hot.
4. Give special attention to hoses, cables and their connections.
5. Check and tighten points of connection and fastening screws for the system components.
6. Replace worn hoses only with hoses of a quality approved by EFD Induction.
7. If dust and dirt have penetrated inside the cabinet, clean the unit inside with a vacuum
cleaner and check for signs of high temperature.
8. Refer to Figure 12–1 Cleaning contact surfaces of coil and HHT. When changing the induc-
tion coil, check that the contact surfaces on both the coil and the transformer terminals are
free of dirt and oxides. If necessary, clean the surfaces with fine emery paper. Also check
that the O-rings for the cooling water seals are free of any dirt or damages.
9. After inspection, close / reinstall the doors / covers. DO NOT connect the system to the
mains supply voltage or attempt to operate it before being certain the covers are correctly
closed.
12.5 Bolts, Nuts and Washers

It is very important to use ONLY stainless steel bolts, nuts and washers. All magnetic steel
parts will super-heat and lead to a critical breakdown. This is due to the electromagnetic field
created by the Sinac.
When replacing missing or worn-out parts ensure that only stainless steel securing parts are
used.
One exception is that ONLY brass nuts can be used to secure the coil.
CAUTION! Use ONLY Stainless steel bolt, nuts and washers.

One exception is that ONLY brass nuts can be used to secure the
coil.

DISTURBANCE OF OPERATION AND CORRECTIVE MEASURES
13 DISTURBANCE OF OPERATION AND CORRECTIVE

MEASURES
Every operational failure results in an interruption of the output power. The FAILURE lamp on
the operating panel, the external failure signal and an alarm message in the operating panel’s
display indicate the fault. Before restarting the converter, find the reason for the alarm and
eliminate the possible cause(s).
DANGER! Do not open the equipment's covers or panels with the

mains supply voltage connected. Refer trouble shooting to qualified
personnel.
Corrective actions should be performed by EFD Induction personnel or qualified on-site main-
tenance personnel. However, the operator may handle the alarm situations set out below that
do not require the removal of covers or panels. If these actions do not restore normal opera-
tion, the operator must record the error message and contact the on-site maintenance person-
nel, EFD Induction Service Department or the nearest EFD Induction representative.
Whenever possible, the operator should manually record the relevant operational data as this
information may be of help in further fault finding. This data will include current, voltage, power
and frequency readings at the time of the fault or just before the fault occurred.
All fault-finding and corrective actions by on-site skilled maintenance per-

sonnel must be performed with the mains supply voltage disconnected.
Always comply with all safety measures when handling electrical equipment, including any na-
tional or international regulations.
DANGER! HIGH VOLTAGE: NEVER perform maintenance with the

doors / covers opened / removed and voltage still connected. The
unit must never be left unsupervised when the doors / covers are
opened / removed. Such conditions involve a risk to life and equip-
ment. Be sure there is no residual voltage in the system when the
doors / covers are opened / removed. The main switch discharges
internal voltages when in the OFF position.
ALSO, CHECK THAT THERE IS NO RESIDUAL VOLTAGE IN COILS

OR OUTPUT UNITS!

13.1 Alarm Messages

The following operational failures are indicated by alarm messages on the operating panels
display. The failures, probable causes and corrective actions are listed below.
Table 13–1 Alarm Messages, Causes and Actions

Alarm Probable Cause Corrective Action
Switch mode power sup- A missing phase. 1. Make sure that the supply voltage
ply alarm consists of all three phases.
Main fuse break.
Indicates a problem on one 2. Check the fuses.
of the SMPS cards. Broken fuse(s) in the SMPS
cards. 3. Any failure on the internal electronic
On Twin units this alarm will circuits must be handled by qualified
stop both outputs. SMPS transformer fuse personnel.
break.
Faulty switch mode power

supply.
Power supply alarm Short circuit in externally 1. Remove externally connected equip-
connected equipment, if any. ment and reset the alarm.
Indicates a problem on the
POWS card. Error on the internal power 2. Any failure on the internal electronic
supply or other internal elec- circuits must be handled by qualified
On Twin units this alarm will tronic circuits. personnel.
stop both outputs.
AC overcurrent alarm AC overcurrent can be 1. Check that the coil is within the sys-
caused by a short circuit in tem performance.
high-power modules such as
converter, capacitors, output 2. Inspect the mentioned systems for
transformers and termina- short circuits.
tions including cables. Most
common is a short circuit in 3. Any failure on the internal electronic
the induction coil or its circuits must be repaired by qualified
terminals. personnel.
It may also be an error on

the internal power supply or
other internal electronic
circuits.

Table 13–1 Alarm Messages, Causes and Actions (cont'd.)

Low frequency alarm Too low or too high fre- 1. Check that the coil is within the sys-
quency is usually caused by tem performance.
High frequency alarm an incorrectly designed in-
duction coil. The coil may 2. Inspect the mentioned systems for
have too large or too small short circuits.
an area, or may be short
circuited. Operation at full 3. Any failure on the internal electronic
load with a very low fre- circuits must be repaired by qualified
quency may also be the personnel.
cause. It may also be an er-
ror on the internal power
supply or other internal elec-
tronic circuits.
Overcurrent driver alarm Possibly caused by a short 1. Check for short circuits in the induc-
in the output circuit or a mal- tion coil and its terminals. Make sure
Indicates an overcurrent in functioning transistor. If the that the workpiece does not short cir-
one of the converters alarm can not be reset, there cuit the coil during operation.
transistors. is a malfunctioning transistor
or it may be an error on the 2. Any failure on the internal electronic
internal power supply or oth- circuits must be repaired by qualified
er internal electronic circuits. personnel.
Inductive An error in the internal fre- 1. Any failure on the internal electronic
quency control system. circuits must be repaired by qualified
Indicates an overly induc- personnel.
tive AC current.
Capacitive An error in the internal fre- 1. Make sure that there are no short cir-
quency control system. cuits in the induction coil or its termi-
Indicates an overly capaci- nals. (Please note that coil and
tive AC current, or a short in Short circuit in the induction terminals must be kept clean to avoid
the output circuit. coil or terminals. the risk of short circuits.)
2. Any failure on the internal electronic

circuits must be repaired by qualified
personnel.
Over temperature The inlet temperature of the 1. Make sure that the inlet cooling
thermostat cooling water is too high. water temperature is below 35°C/95°F.
If the temperature has been too high, it
Indicates that the tempera- Excessive heat developed in might take some time before the alarm
ture of one of the thermo- water cooled power can be reset. Let the water flow through
stats monitoring the cooling components. the converter.
system is too high.
It may be an error in the in- 2. With the mains disconnected, in-
On Twin units this alarm will ternal electronic circuits. spect for overheated components.
stop both outputs.
personnel.


Over temperature The inlet temperature of the 1. Make sure that the inlet cooling
Inlet water cooling water is too high. water temperature is below 35°C/95°F.
If the temperature has been too high, it
Indicates that the tempera- It may be an error in the in- might take some time before the “Over-
ture of the cooling water is ternal electronic circuits. temp Water” alarm can be reset. Let
too high. the water flow through the converter.
(The “Auto Water Shut-Off control func-
On Twin units this alarm will tion must not be activated)
stop both outputs.
2. If the EOR function is activated, see
technical description table.

personnel.
Water flow low Clogged water filter in water 1. Check that external manual valves
inlet terminal. are open.
1, 2, 3, 4, 5, 6
Low differential cooling 2. Make sure that cooling water supply
Indicates insufficient water water pressure. to the FC is adequate to technical spec-
flow through a cooling ification. See rating plate and technical
circuit. Insufficient water flow description tables.
through cooling circuit.
3. Clean the inlet water filter. Disable
Insufficient water flow the water inlet supply, retract the filter
through the induction coil. and clean it with compressed air.
4. Make sure that the heating coil al-

lows for enough water flow. Redesign
the coil if necessary.
5. If the EOR function is activated, see

technical description table.
External Fault The water flow from the Make sure that the heating unit allows
heating unit is low or the for enough water flow.
Customer-defined alarm (e. temperature is too high.
g., external interlock alarm,
external water flow alarm,
etc.)


EXTERNAL STOP COM- The external/emergency 1. Before restarting the unit after an ex-
MAND or EMERGENCY stop command has been ac- ternal/emergency stop command, find
STOP! tivated externally or the the reason for the activation of the
doors of the FC have been emergency stop function.
Indicates that the emer- opened.
gency stop has been 2. To reset the emergency stop com-
activated. mand function, re-establish the emer-
gency stop command signal on the
On Twin units this alarm will external connection.
stop both outputs.
3. Press the RESET button to make the
unit ready for use.
DC Voltage too low The main voltage is too low. 1. Check that the main voltage is within
the limit.
The DC voltage on the recti- One phase is missing.
fier is too low. 2. Make sure that the supply voltage
There was a temporary drop consists of all three phases.
in the main voltage.
DC Voltage too high 3. Check that the main voltage is within
The main voltage is too high. the limit.
On Twin units this alarm will
stop both outputs. There was a temporary high
main voltage.
Power on by startup There was a “Power on com- Release any stuck power on buttons or
alarm mand” detected by the con- signals, and press the RESET button to
trol system during startup. make the unit ready for use.
DC Overvoltage detected There was a high voltage Check the main voltage supply for
peak on the DC capacitor. noise peaks from other equipment con-
On Twin units this alarm will nected to the same supply.
stop both outputs. In Twin units, this can be
caused by using the two in- Make sure induction coils do not influ-
duction coils simultaneously ence each other by increasing distance
on the same workpiece with or apply magnetic screening between
a short distance between coils.
coils.
Ground fault detected The output transformer had 1. Check the main voltage supply for
an internal flash over. noise peaks from other equipment con-
nected to the same line.
Internal circuits are shorted
to ground. 2. Any failure on the internal electronic
personnel.


Ground fault 2 detected The induction coil was 1. Make sure that the induction coil is
grounded. not connected to ground during
heating.
The output transformer had
an internal flash over 2. Check the main voltage supply for
noise peaks from other equipment con-
Internal circuits are shorted nected to the same line.
to ground.
personnel.
Fuse Fan Broken fan motor. Any failure on the internal electronic cir-
cuits must be repaired by qualified
Indicates that the current Internal electronic failure. personnel.
limiter for optional electronic
rack cooling fan is active.
On Twin units this alarm will

stop both outputs.
System reset by Watch For safety reasons, the mi- 1. Press the RESET button to make the
Dog Timeout cro controller is reset auto- unit ready for use.
matically if a software or
On Twin units this alarm will hardware condition stops it 2. Any failure on the internal electronic
stop both outputs. from operation. The unit will circuits must be repaired by qualified
be restored as after a start- personnel.
up. After such a reset, this
alarm will be active.
Overtemp Inverter Clogged water channels in 1. Press the RESET button to make the
inverter. unit ready for use if possible.
Indicates a too high temper-
ature at the inverter heat Damaged transistors in 2. Inspect water flow in inverter.
sink. inverter.
On Twin units this alarm will Electronics fault. circuits must be repaired by qualified
stop both outputs. personnel.
Main contactor off The main contactor is not Refer to the emergency stop alarm.
energized because the
On Twin units this alarm will Emergency stop was Press reset button.
stop both outputs. activated.
DC overcurrent detected High voltage peak on incom- Check the main voltage supply for
ing supply. noise peaks from other equipment con-
Indicates an overcurrent in nected to the same supply.
the DC circuit Internal electronic failure.
Any failure on the internal electronic cir-
On Twin units this alarm will cuits must be repaired by qualified
stop both outputs. personnel.


LifeBit time out alarm Bus cable disconnected. 1. Reset.
Bus communication failure. Life Bit function not imple- 2. Check connections.
mented in external control
system. 3. Make sure external control system
follows fieldbus interface description.
External control system
failed. 4. Check external control system.
Internal electronic fail. 5. Any failure on the internal electronic

personnel..
No lights on control panel Electronics’ power supply Refer to Power supply alarm.
failure.
Indicates lack of electronics’
power supply.

REGISTRATION FORM FOR FAULT FINDING
14 REGISTRATION FORM FOR FAULT FINDING

In the event of irregularities and failures that can not be solved by qualified on-site mainte-
nance personnel, contact the EFD Induction Service Department or the nearest EFD Induction
representative (refer to Section 15 EFD INDUCTION ADDRESSES). Beforehand, record the
relevant operational data to assist additional fault finding. Use the following form.
A. Equipment Identification
EFD Induction Project No. ____________________________________
Equipment Serial No.: ____________________________________
Type of ECU, if any: ____________________________________
B. Readings at the time of the fault / just before the fault occurred:
DC POWER: ____________________________________ kW
DC VOLTAGE: ____________________________________ V
AC CURRENT: ____________________________________ A
FREQUENCY: ____________________________________ kHz
C. Conditions prior to / at the time of the fault:

Type and size of coil: ____________________________________
Type and size of workpiece: ____________________________________
Fault occurred at: Start-up / Continuous operation / Cycle operation

Any changes to setup prior to ____________________________________
fault:
______________________________________________________________________________
D. Control functions in use (Timer/Sequence):
______________________________________________________________________________
E. Activated Alarm messages at the moment of failure:
______________________________________________________________________________

EFD INDUCTION ADDRESSES
15 EFD INDUCTION ADDRESSES

More than 65 years experience has given us unrivalled knowledge of diverse applications.
Worldwide network of representatives, manufacturing facilities and sales and service compa-
nies. Contact us at sales@efd-induction.com
Europe
Head Office Norway Germany

EFD Induction Group EFD Induction AS EFD Induction GmbH
Bøleveien 4 Bøleveien 10 Lehener Strasse 91
P.O. Box 84 Sentrum P.O. Box 363 Sentrum Postfach 426
N-3701 Skien N-3701 Skien D-79004 Freiburg
Norway Norway Germany
Tel.: +47-35 50 60 00 Tel.: +47-35 50 60 00 Tel.: +49-761-8851-0
Austria Denmark France

EFD Induction Ges.m.b.H EFD Induction AS EFD Induction S.A
Perfektastraße 87 / Top 5 Hasselhaven 49 11 Z.I. du Fond des Prés
A-1230 Vienna DK-8520 Lystrup F-91460 Marcoussis
Austria Denmark France
Tel.: +43-1-914 23 16 Tel.: +45-40 30 84 35 Tel.: +33-1-6901 4664
Italy Poland EFD Induction S.A

EFD Induction S.r.l EFD Induction Sp. z.o.o. 20, avenue de Grenoble
Via Della Birona, Gen J. Sowinskiego 3 B.P. 30, F-38171
30/32 I-20052 Monza MI Gliwice 44101 Seyssinet Pariset
Italy Poland Cedex, France
Tel.: +39-039-32-3320 Tel.: +48 32 237 62 27 Tel.: +33-4-7649 3250
Spain Sweden Romania

EFD Induction s.l.u. EFD Induction AB EFD Induction S.R.L.
Los Palangreros No. 5 Kokillgatan 3 Calea Bucuresti no. 20,
Entreplanta-Trasera Box 200 47 Village Vidra
E-48920 Portugalete (Bizkaia) S-720 20 Västerås 077185 Ilfov
Spain Sweden Romania
Tel.: +34-94–472 09 36 Tel.: +46-21-300010 Tel.: +40-21 332 1948
Russia United Kingdom

EFD Induction a.s EFD Induction Ltd.
Moscovskiy prospect, 97A, Units 1&2, Wedn. Way Ind. Estate
Office 505 Well Lane, Wednesfield
196084, Saint Petersburg Wolverhampton, WV11 1XP
Russia United Kingdom
Mob.: +7 921 947 64 31 Tel.: +44-1902 308800

EFD INDUCTION ADDRESSES
Asia
Korea Thailand Japan
EFD Induction Korea Co. Ltd EFD Induction Co. Ltd. EFD Induction K.K.
Sejong B/D #504 1350/150-151 Thairong Tower ERVIC Yokohama 11 floor
Sangli-ro 10 GII 36 Building B, 10th Fl. 65 Yoshidamachi Naka-ku
Gangdong-gu Phatthanakan Rd. Yokohama city,
Seol 05288 Suan luang Kanagawa 231-0041
Korea Bangkok Japan
Tel.: +82 2 6929 4620 10250 Thailand Phone: +81(0) 45 231 5011
Tel: +66–2757–4128
China China China
EFD Induction Co. Ltd. EFD Induction Co. Ltd. EFD Induction Co. Ltd.
Bldg. H, No. 1688, Beijing Branch Guangzhou Branch
Zhuan Xing Road Room 1601A, CBD Intl. Mansion 4th Floor, Building A2
Xin Zhuang Industrial Park No.16 Yong´an Dongli Youbao Industrial Park
Shanghai 201 108 Chaoyang District No.17 Xiangshan Road
China Beijing 100022 Guangzhou Science Park
Tel.: +86-21-5442 0227 China Luogang District 510663
Tel.: +86-10-6588 8691 China
Tel.: +86-20-62863250
India Malaysia
EFD Induction Private Ltd. EFD Induction Sdn. Bhd.
Plot no. 43 & 44 No. 12, Jalan Tambur 33/19
KIADB Bengaluru Aerospace Shah Alam Technology Park
Park 40440 Shah Alam
Budigere Post Selangor
Bengaluru North Taluk – Kuala Lumpur
562129 Malaysia
Karnataka Tel.: +6016 3304217
India
Tel.: +91-80-666 90 400
USA and South America
USA Electronic Heating Equipm. Inc. Brazil

EFD Induction Inc. 281120 Hwy. 410, Unit B-5 EFD Induction Ltda.
31511 Dequindre Rd. P.O. Box 659 Rua Antônio Carlos de Barros
Madison Heights, MI 48071 Buckley, WA 98391 Bruni 136
USA USA 18052-017 – Sorocaba – SP
Tel.: +1-248-658 0700 Tel.: +1-360-829-0168 Brasil
E-mail: sales@impeder.com Tel: +55 (15) 3031 4562
Web: www.impeder.com
Contact us at sales@efd-induction.com
or, visit us at www.efd-induction.com
For technical support and 24 Hour Service Hot line support, see www.
efd-induction.com

1 - User Manual Sinac 6-50 Rev B - EN

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SINAC®

Sinac 6–50 Series

Document 00139398 | Rev. B. | September 27, 2017 Page i www.efd-induction.com

Document 00139398 | Rev. B. | September 27, 2017 Page ii www.efd-induction.com

Document 00139398 | Rev. B. | September 27, 2017 Page iii www.efd-induction.com

1.1 Induction Heating

Document 00139398 | Rev. B. | September 27, 2017 Page 1 www.efd-induction.com

2.1 Restrictions in Use

Document 00139398 | Rev. B. | September 27, 2017 Page 2 www.efd-induction.com

2.2 Qualified Personnel

Document 00139398 | Rev. B. | September 27, 2017 Page 3 www.efd-induction.com

3.1 Safety Signs

Information, or notice, provides additional information to a particular para-

Document 00139398 | Rev. B. | September 27, 2017 Page 4 www.efd-induction.com

Anyone operating, maintaining, or working in close proximity to the equip-

Please note the following:

The personnel protective equipment (PPE) recommended for users are

3.3 Electric Shocks

DANGER! Electrical shocks can result in personal injury or loss of

Document 00139398 | Rev. B. | September 27, 2017 Page 5 www.efd-induction.com

To avoid the risk of an electric shock:

Do not cut or damage the supply cables to the frequency converter.

Do not open the equipment covers during maintenance without setting

3.4 Heated Objects

WARNING! Heated objects can cause fire or burns.

To prevent the danger of fire or burns:

Document 00139398 | Rev. B. | September 27, 2017 Page 6 www.efd-induction.com

3.5 Electromagnetic Fields

CAUTION! Electromagnetic fields can be a health risk.

To avoid hazards to personal health:

Persons with pacemakers, heart valves or metal pins, plates or other

Anyone with an implant, regardless of type, or pregnancy should consult

3.6 Touching the Induction Coil on Manually Operated Equipment

Document 00139398 | Rev. B. | September 27, 2017 Page 7 www.efd-induction.com

Using dry, undamaged, non-conductive gloves is recommended when

The equipment must be grounded, and the equipment grounding system

3.7 Touch Voltage at the Coil

Document 00139398 | Rev. B. | September 27, 2017 Page 8 www.efd-induction.com

4 TRANSPORT, STORAGE AND RECYCLING / DISPOSAL

DANGER OF DAMAGE with improper transport. DO NOT lay the

WARNING! Never stand under load while lifting!

Figure 4–1 Lifting by crane.

Document 00139398 | Rev. B. | September 27, 2017 Page 9 www.efd-induction.com

4.3 Recycling / Disposal

The collection, treatment and recycling of electric devices is extremely

Document 00139398 | Rev. B. | September 27, 2017 Page 10 www.efd-induction.com

5.1.1 Lifting the Equipment with Hoisting Belts

With systematic distribution of the load, the

90° 60° 45°

Document 00139398 | Rev. B. | September 27, 2017 Page 11 www.efd-induction.com

Avoid damaging the connections

CAUTION! DO NOT stand the crate

Fig. 5–2 Step by step instructions for unpacking

5.2 Mounting the Sinac

Figure 5–3 Sinac free space needed.

Document 00139398 | Rev. B. | September 27, 2017 Page 12 www.efd-induction.com

Figure 5–4 Sinac mounting brackets.

5.2.1 Cabinet Attached to a Frame (Optional)

Extendable support legs are equipped on the