Eges

EGES
INDUCTION MELTING SYSTEM

ENERGY COUNTER DISPLAY
OPERATING MANUAL
EGES.KK.07.01.GB.01
March 2004
EL E KT R K E LE K TR O N K G ER E LE R S A N A Y A . .
i
EGES.KK.07.01.GB.01 Ener gy Co unt er Displ ay O perating M anual
I MPORTANT This document contains data current as of publication date and is
subject to change by EGES without notice.
N OTI CE
EGES Elektrik Elektronik Gerecler A.S. reserves the right to make
changes to operating and maintanence manuals of induction melting
systems without notice. EGES advises its customers to obtain the
latest version of Operating Manuals.
It is necessary to read the operating and maintanence manuals

carefully to operate EGES Induction Melting System in the most
productive way.
EGES Induction Melting System Operating and Maintanence Manuals

can not be printed without permission.
ABOUT THIS EGES Inducton Melting System Energy Counter Display Operating
Manual includes necessary information about Energy Counter
MANUAL equipment and its display used in EGES Induction Furnace Systems.
For summary of updates in this book, see, Appendix, Summary of

Updates of EGES Induction Melting System Energy Counter Display
Operating Manual.
INFORMATION ABOUT This book contains cautions.

CAUTIONS
CAUTION This is an example of a caution statement. The information in a caution is

provided to prevent from faults that may occur during the operation of
induction melting system. Please read each caution carefully.
ii
CONTENTS ......................................................................................................................... PAGE
1 INTRODUCTION ................................................................................................................. 1-1
2 ENERGY COUNTER DISPLAY ............................................................................................. 2-1
2.1 DISPLAY ......................................................................................................... 2-1
2.2 MENUS ........................................................................................................... 2-1
2.2.1 Man Menu.................................................................................................... 2-1
2.2.2 Setup Menu .................................................................................................. 2-2
2.2.2.1 Output Power ........................................................................................... 2-3
2.2.2.2 Input Current ............................................................................................ 2-4
2.2.2.3 Input Voltage ............................................................................................ 2-4
2.2.2.4 Output Voltage ......................................................................................... 2-4
2.2.2.5 DC Voltage ............................................................................................... 2-4
2.2.2.6 The Number Of Rectifiers ........................................................................ 2-5
2.2.2.7 Type Of The Rectifier ............................................................................... 2-5
2.2.2.8 Resetting Energy...................................................................................... 2-5
2.2.2.9 Communication Address .......................................................................... 2-6
2.2.2.10 Default Setup ....................................................................................... 2-6
2.3 COMMUNICATION ............................................................................................ 2-7
3 APPENDIX..................................................................................................................... 3-1
3.1 INDEX ............................................................................................................. 3-1
3.2 HISTORY OF THE REVISIONS ........................................................................... 3-2
3.3 QUESTIONNAIRE ............................................................................................. 3-3
iii
1 INTRODUCTION
EGES Induction Furnace Systems are equipped with Energy Counter for displaying the input current
and voltage, output current and voltage, operating frequency, active, reactive power and energy. This
equipment is designed by EGES only for Induction Furnace Systems, and it is not possible to use this
equipment for a different purpose.
In this book, the information displayed on Energy Counter screen will be explained.
Short History of Eges
In 1975 it is instituted under the name EGESAN. Thyristor Controlled Rectifier is produced by
EGESAN for the first time in Turkey, in the same year.
In 1977 again for the first time in Turkey:
Thyristor controlled inverter;
Thyristor controlled uninterruptible power supply;
Reactive power control relay,
Are produced.
In 1981 companys name changed as EGES A.
EGES continues its existence as the first and only company producing induction furnace systems in
Turkey, since 1984.
Improving induction melting system from day to day, EGES included PLC to its systems in 1993.
Today, over 300 EGES Induction Furnaces are in operation in and out of the country. Systems reached
a power range changing from 75 kW to 5 MW and a capacity range between 100 kg/h and 8 tone/h.
Besides the melting systems, holding and heating systems are also produced in EGES.
At first Siemens S5-95U model PLC was used in EGES Induction Furnaces. Siemens C7-63x series are
in use in EGES systems, since 2000.
1-1
2 ENERGY COUNTER DISPLAY
2.1 DISPLAY
When the system first fed, introduction page will be displayed. Introduction page is shown below:

In a short while the screen changes as shown below:

Here mimicx01 indicates the name and type of the display board. The date at the right side of this is
the revision date of the program loaded. This page skips to main page after a short while.
2.2 MENUS
2.2.1 MAIN MENU
Main menu consists of two pages. The first page is shown below:

!"
# $%&
' $'&
The symbols on this page are:
Vo :Output (inverter) voltage [V].
PF :Power factor.
Fo :Output (inverter) operating frequency [Hz].
Io :Output (inverter) current [A].
Ea :Active energy (input) [kWh].
2-1
Er :Reactive energy (input) [kVArh].
When any one of the two keys in the middle of the key set is pressed, the second page of the main
menu is displayed.
() *
! $ *
!# $% !"
!' $' # +
The symbols on this page are:
Vdc :Rectifier voltage [V].
Vi :Input voltage [V].
Ii :Input current [A].
PF :Power factor.
P :Appearent power (input) [kVA].
Pa :Active power (input) [kW].
Pr :Reactive power (input) [kVAr].
a :Inverter triggering angle [].
When Left ARROW key is pressed Vdc will change to Po and PF will change to t as seen below.
! $% *

! $ *
!# $% , -.
!' $' # +
New symbols here are:
Po :Output (inverter) power [kW].
t :Time corresponding triggering angle [us].
2.2.2 SETUP MENU
There is an energy counter setup menu also. You can enter setup parameters here, according to
converter type and power and also the specifications of the system. These parameters can only be
entered by Eges service personnel. Otherwise energy counter may run faulty.
2-2
Main page of the setup menu is shown below:
/ 0! -,!12' 3 4
0 * 56-''25,3
0* 567,#823
0
! 3 94 :
Symbol U, on the right bottom corner of the page, corresponds to up arrow and the symbol D
corresponds to down arrow. Only arrow keys will be displayed on the page.
You can see the necessary parameter by using up and down arrow keys. * symbol will be displayed on
the left side and > symbol on the right side of the selected parameter. By pressing > key you can go
to the setup page of this parameter. Setup for all the parameters are similar. So setup for one parameter
will be explained here. For what purpose, the other parameters are used, will be explained also.
2. 2. 2. 1 O u tp ut P ow er
On this page measured output power can be setup roughly. The Value shows currently measured
value. Cns, shows newly entered coefficient, and Old shows current coefficient. When you first enter
the page these two values are equal.
0!3 -,!12'
#7-2;
5.; <= 7(; <=
0
! 3 9 :
For increasing the coefficient value press up arrow key and for decresing the coefficient value press
down arrow key. When you press any of these keys Cns value changes and enter symbol ( letter
E on the figure ) on the right bottom corner is displayed. This means that, the coefficient is changed
but you must press the enter key to accept this value.
0!3 -,!12'
#7-2;
5.; <= 7(; <=
0
! 3 9 :
When you accept the new value Value will also change.
CAUTION If you can not adjust the exact measurement value by this setup you must
make the sensitive adjustment by the potansiometers on the dispc06 board.
But you must not forget that there is high voltage on the board.
After finishing setup press < key to return to the main menu, or if you dont press any key for a while
the page automatically returns to the main menu.
2-3
2. 2. 2. 2 I np ut C ur ren t
On this page input current can be setup roughly. Setup page is shown below.
0 *3 56-''25,
#7-2;
5.; <= 7(; <=
0
! 3 9 :
2. 2. 2. 3 I np ut Vo l tag e
On this page input voltage can be setup roughly. Setup page is shown below.
0*3 567,#82
#7-2;
5.; <= 7(; <=
0
! 3 9 :
2. 2. 2. 4 O u tp ut V o lt ag e
On this page output voltage can be setup roughly. Setup page is shown below.
03 -,7,#82
#7-2;
5.; <= 7(; <=
0
! 3 9 :
2. 2. 2. 5 DC V olt ag e
On this page DC busbar or rectifier voltage can be setup roughly. Setup page is shown below.
0()3 : 7,#82
#7-2;
5.; <= 7(; <=
0
! 3 9 :
2-4
2. 2. 2. 6 Th e Nu mb e r O f R e ct if ie rs
On this page you can determine, the number of rectifiers, which changes according to the system type.
Calculation method changes according to the type and number of rectifiers. Setup page is shown below.
02), )-5, 3
5.; 7(;
0
! 3 9 :
You must enter 1 if the rectifier number is 1, and 2 if the rectifier number is 2.
2. 2. 2. 7 T yp e O f T he R e cti f ie r
If there are more than one rectifiers in the system, the value on this page must be changed according to
the connection type of the rectifiers. Setup page is shown below.
02), ,>62 3
5.; 7(;
0
! 3 9 :
If the number of rectifiers is 1, this parameter is 1 as default, and can not be changed.
If the number of rectifiers is different than 1, then you can enter 1 for parallel connection and 2 for
serial connection type.
CAUTION If the rectifier number is selected as 1 later on, then rectifier type again
changes to default value 1.
2. 2. 2. 8 Re s ett in g E n e rg y
As seen on the main menu, this system records the consumed energy at the same time. Recorded
active and reactive energies can be reset on this page. The page is shown below.
0 2 . 2 , 2 5 2 ' 8> 3
5 ,* 5 - 2 4
9 .)#62
0
! 3 94
2-5
On this page, recorded energy values can be reset by pressing > key. When you press this key a
message is displayed. The message is shown below.
02.2, 252'8> 3
6(#,*58
0
! 3 94
After a short while, main page of the setup menu will be displayed. If you dont want to reset energies,
you can exit this page by pressing < key.
2. 2. 2. 9 Co mmun ic at io n Ad d r es s
If the induction furnace system is equipped with Promelt SCADA program, PLC gets data from the
Energy Counter System with a serial connection. A communication address must be chosen for this
purpose. This value is 65 for the first converter, 66 for the second converter and 67 for the third
converter. These values must be entered on every Energy Counter display one by one.
0?? (('2.. 3
5.,; 7(;
0
! 3 9 :
Please see section 2.3 Communcaton for communication protocol and for connection with a different
device.
2. 2. 2. 10 Def au lt S et up
When first adjusting the Energy Counter, during test process of Induction Furnace System, at Eges, this
function is used. This function adjusts default values for all setup parameters. Then, service personnel
must adjust new parameters one by one.
0., 77 5.,3

5,*5-2 4
9 .)#62
0
! 3 94
2-6
On this page you can start changing the parameters to the default values, by pressing > key. The page
displayed when you press this key is shown below.
0 ., 77 5.,3

6(#,*58
0
! 3 94
After a short while, main page of the setup menu will be displayed. Now all analog values are 271.
Rectifier type is 1, number of rectifiers is 1 and communication address is 65. If you dont want to
change the default values you can exit this page by pressing < key.
2.3 COMMUNICATION
Energy counter can communicate with a computer or any device which can make serial communication.
Communication feature is on mimicx board. Communication port is designed for RS-422 protocol.
Setup parameters for communication are; 9600baud, 1 stop, 1 start and 8 data bits.
Question consists of 2 bytes:
Byte no: Value:
0 Character Q
1 Communication address. See: 2.2.2.9 Communication Address.
Answer consists of 40 bytes:
Byte no: Value: Unit:
0:1 Output Active Power [kW]
2:3 Output Voltage [Vac]
4:5 Output Current [Adc]
6:7 DC Voltage [Vdc]
8:9 Input Voltage [Vac]
10:11 Input Current [Iac]
12:13 Reserved
14:15 Reserved
16:17 Thyristor Toff time. If there is no dot microseconds, otherwise 16:17

miliseconds.
18:19 Frequency [Hz]
20:21 Alfa angle [Degree]
22:23 Input Reactive Power [kVAr]
24:25 Input Appearent Power [kVA]
26:27:28:29 Active Energy [kWh]
2-7
30:31:32:33 Reactive Energy [kVArh]
34.0 Dot. For Thyristor Toff time.
34.1,...,34.7 Reserved;
35 Reserved;
36:37 Power Factorx10.
38:39 Input Active Power [kW]
If a character other than Q is received with the question, then the answer will be E001.
If the communication address in the question is different from the address in the energy counter, then
the program will not answer.
2-8
3 APPENDIX
3.1 INDEX
symbols
a .................................................................... 2-2
I Ea .................................................................... 2-2
Introduction Page.................................................. 2-1 Er .................................................................... 2-2
Fo .................................................................... 2-1
Ii .................................................................... 2-2
P Io .................................................................... 2-1
P .................................................................... 2-2
pcb Pa .................................................................... 2-2
dispc06............................................................. 2-3 PF ............................................................. 2-1, 2-2
mimicx.............................................................. 2-7 Po .................................................................... 2-2
mimicx01.......................................................... 2-1 Pr .................................................................... 2-2
PLC ...................................................................... 2-6 t .................................................................... 2-2
Promelt ................................................................. 2-6 Vdc................................................................... 2-2
Vi .................................................................... 2-2
S Vo .................................................................... 2-1
SCADA ................................................................. 2-6
3-1
3.2 HISTORY OF THE REVISIONS
Version No Revision No Date Explanation
01 01 March 2004 First published
3-2
3.3 QUESTIONNAIRE
Your opinion is important for us.
We request you to fill our questionnaire which will help us to develop our manual.
Please fax the questionnaire you filled to us.
Our Address:
EGES ELEKTRK VE TAOCAI YOL U 1. SK. N O:10

34550 BACILAR
ELEKTRONK A..
STANBUL / TRKYE
Tel/Fax +90 212 446 41 21 / +90 212 446 41 27
e-mail eges@eges.com.tr
Your Address:
Name
Occupation
Company/Depart.
Address
Post Code/City
Country
Tel/Fax
e-mail
Please evaluate the following questions between 1(bad) and 5(very good) :
Is the content of the book meets your expectations?
Can you easily reach the information you need?
Can the content of the book easily be understood?
Are the figures in the book sufficient?
Other
suggestions:
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INDUCTION MELTING SYSTEM

It is necessary to read the operating and maintanence manuals

EGES Induction Melting System Operating and Maintanence Manuals

For summary of updates in this book, see, Appendix, Summary of

INFORMATION ABOUT This book contains cautions.

CAUTION This is an example of a caution statement. The information in a caution is

Short History of Eges

In 1977 again for the first time in Turkey:

Thyristor controlled inverter;

Thyristor controlled uninterruptible power supply;

Reactive power control relay,

In 1981 companys name changed as EGES A.

 

In a short while the screen changes as shown below:

 

2.2.1 MAIN MENU

The symbols on this page are:

Vo :Output (inverter) voltage [V].

Fo :Output (inverter) operating frequency [Hz].

Io :Output (inverter) current [A].

Ea :Active energy (input) [kWh].

The symbols on this page are:

Vdc :Rectifier voltage [V].

Vi :Input voltage [V].

Ii :Input current [A].

P :Appearent power (input) [kVA].

Pa :Active power (input) [kW].

Pr :Reactive power (input) [kVAr].

a :Inverter triggering angle [].

! $% * 

New symbols here are:

Po :Output (inverter) power [kW].

t :Time corresponding triggering angle [us].

2.2.2 SETUP MENU

0., 77 5.,3

0 ., 77 5.,3

Question consists of 2 bytes:

Byte no: Value:

1 Communication address. See: 2.2.2.9 Communication Address.

Answer consists of 40 bytes:

Byte no: Value: Unit:

0:1 Output Active Power [kW]

2:3 Output Voltage [Vac]

4:5 Output Current [Adc]

6:7 DC Voltage [Vdc]

8:9 Input Voltage [Vac]

10:11 Input Current [Iac]

16:17 Thyristor Toff time. If there is no dot microseconds, otherwise 16:17

18:19 Frequency [Hz]

20:21 Alfa angle [Degree]

22:23 Input Reactive Power [kVAr]

24:25 Input Appearent Power [kVA]

26:27:28:29 Active Energy [kWh]

34.0 Dot. For Thyristor Toff time.

36:37 Power Factorx10.

38:39 Input Active Power [kW]

SCADA ................................................................. 2-6

01 01 March 2004 First published

Please fax the questionnaire you filled to us.

EGES ELEKTRK VE TAOCAI YOL U 1. SK. N O:10

Is the content of the book meets your expectations?

Can you easily reach the information you need?

! $% *

0., 77 5.,3

0 ., 77 5.,3