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100kW Induction heating controller is specially designed for the application of pipeline heating and plane heating equipment, such as plastic machinery, food machinery, aluminum plastic machine, drum equipment, heating, boiler, oil, and natural gas transmission, etc. With stronger industry pertinence and better energy-saving effect, this product adopts the fifth generation DSP digital processing platform technology of our company, open application structure, wide inductance to adapt to the coil range, through the digital programmable control system, it can realize the special functions of different customers and different occasions, which brings great convenience to customers. It is an Induction heating transformation project and supporting heating equipment Products.
The move from conventional heating methods to induction heating technology is a significant leap in efficiency and precision for many industrial processes. At the heart of this system lies the Induction Heating controller, the brain that manages power, temperature, and overall performance. A smooth, professional installation is crucial for maximizing the benefits of this advanced technology.
This guide simplifies the installation and commissioning of a complete Induction Heating controller and heater system, ensuring a high-quality, long-lasting setup.
Before making any changes, thorough documentation is essential. This step ensures that the original setup can be restored if necessary and provides a baseline for comparison.
Wiring Audit and Photography: Carefully inspect the existing equipment wiring. Take clear, well-lit photos and create detailed, labeled diagrams (or use colored markers) to document the original connections. This prevents confusion later in the process.
Safety First: Confirm that the main power is secured and locked out before beginning any work.
The location of the central Induction Heating controller unit (the control board or electrical cabinet) directly impacts cable length, accessibility, and maintenance.
Determine Mounting Position: Select a cool, dry, and easily accessible spot for the Induction Heating controller enclosure. Ensure adequate ventilation.
Measure Wire Runs: Calculate the necessary length of the high-temperature power cable that will lead from the Induction Heating controller to the coil.
Stakeholder Consultation: Always review and confirm the placement and cable lengths with the facility's master electrician or plant foreman to ensure compliance with local electrical codes and operational workflow.
Accurate power measurement is fundamental to selecting the correct Induction Heating controller and coil for the application.
Initial Power Measurement: Accurately measure the power requirements of the existing system or the intended load. This data is critical for sizing the new Induction Heating controller and ensuring it operates within its safe range.
Documentation: Record the measured data and take photos of the original equipment nameplates. These records are vital for verification.
Installation Power Calculation: Use the measured data to confirm the final installation power. This step ensures the entire Induction Heating controller system is neither under- nor over-powered.
The preparation of the heating surface (often a barrel or pipe) is key to efficiency and accurate temperature control by the Induction Heating controller.
Measure and Cut Insulation: Measure the circumference of the barrel to determine the precise size needed for the insulation cotton. Proper insulation minimizes heat loss.
Form Preparation: Size the supporting insulation board (e.g., yellow wax board) that will hold the coil.
Probe Hole Placement: Carefully mark and drill the access hole for the temperature sensor (probe). The size and depth of this hole must be accurate to ensure the Induction Heating controller receives reliable temperature feedback for precise control.
Zone Definition: Clearly define and fix the boundaries of each temperature control zone if the system uses multiple heating sections.
The induction coil is the workhorse; its winding quality directly affects system efficiency and the performance of the Induction Heating controller.
High-Temperature Wire Length: Determine the exact length of the high-temperature wire required for the coil, accounting for the number of turns and spacing.
Aesthetic and Structural Winding: Wind the coil to ensure a neat and professional appearance. Crucially, maintain uniform pitch size control (the distance between turns) and ensure the winding is tight against the barrel.
Post-Winding Inductance Check: Use a suitable meter (paying close attention to its range) to measure the total inductance of the newly wound coil. This measurement is vital for ensuring compatibility and peak efficiency with the Induction Heating controller unit.
This is the integration phase where the Induction Heating controller is brought online.
Breaker and Meter Confirmation: Verify the rating and range of the existing circuit breaker and ammeter. If they are too small for the new load, they must be upgraded or replaced before proceeding.
Power-Up and Independent Testing: Connect the wiring and test each heating zone or component separately. Measure the voltage and current to confirm they are within the normal operating range specified by the Induction Heating controller manufacturer.
Troubleshooting: Address any electrical issues (voltage drops, current spikes) systematically. Once individual zones are stable, perform a full system test with the Induction Heating controller managing the entire load.
A successful installation concludes with meticulous cleanup and final documentation.
Site Cleanup: Completely clear and clean the installation area. Professionalism includes leaving the site in a pristine condition.
Operational Handover: Provide a complete operational check and training on the Induction Heating controller interface for the end-user or plant personnel.
By following these professional steps, you ensure the robust and efficient operation of your Induction Heating controller system, delivering energy savings and superior process control for years to come.
In order to ensure that the original production process is unchanged after the original equipment is switched to the electromagnetic heating coil, the original operating procedure is unchanged, and the performance difference between the two heating methods is designed. The electromagnetic heater has been reduced by about 30% of power usage, and is heated by electromagnetic heating. Power adjustment and power protection functions are designed on the controller. So the debugging process is quite simple, the user can debug according to the instructions.
| Name | Performance parameter |
| rated power | Three-phase 100KW |
| Rated input current | 120-150(A) |
| Rated output current | 240-260(A) |
| Rated voltage frequency | AC 380V/50Hz |
| Voltage adaptation range | constant power output at 300 ~ 400V |
| Adapt to ambient temperature | -20ºC~50ºC |
| Adapt to environmental humidity | ≤95% |
| Power adjustment range | 20% ~ 100% stepless adjustment(That is: adjustment between 0.5 ~ 100KW) |
| Heat conversion efficiency | ≥95% |
| Effective power | ≥98%(Can be customized according to user needs) |
| working frequency | 5~40KHz |
| Main circuit structure | Full bridge series resonance |
| Control System | The DSP-based high-speed automatic phase-locking tracking control system |
| Application mode | Open application platform |
| monitor | Programmable digital display |
| start time | <1S |
| Instantaneous overcurrent protection time | ≤2US |
| Power overload protection | 130% instantaneous protection |
| Soft start mode | Fully electrically isolated soft start heating/stop mode |
| RS485 communication | Modbus RTU standard communication protocol |
| Support PID adjustment power | Identify 0-5V input voltage |
| Support 0 ~ 1000 ºC load temperature detection | Accuracy up to ± 1 ºC |
| Adaptive coil parameters | Double 35 square line, length 35m, inductance 85 ~ 100uH |
| Coil to load distance(Thermal insulation thickness) | 20-25mm for circle, 15-20mm for the plane, 10-15mm for ellipse and within 10 mm for superellipse |
100kW Induction heating controller is specially designed for the application of pipeline heating and plane heating equipment, such as plastic machinery, food machinery, aluminum plastic machine, drum equipment, heating, boiler, oil, and natural gas transmission, etc. With stronger industry pertinence and better energy-saving effect, this product adopts the fifth generation DSP digital processing platform technology of our company, open application structure, wide inductance to adapt to the coil range, through the digital programmable control system, it can realize the special functions of different customers and different occasions, which brings great convenience to customers. It is an Induction heating transformation project and supporting heating equipment Products.
The move from conventional heating methods to induction heating technology is a significant leap in efficiency and precision for many industrial processes. At the heart of this system lies the Induction Heating controller, the brain that manages power, temperature, and overall performance. A smooth, professional installation is crucial for maximizing the benefits of this advanced technology.
This guide simplifies the installation and commissioning of a complete Induction Heating controller and heater system, ensuring a high-quality, long-lasting setup.
Before making any changes, thorough documentation is essential. This step ensures that the original setup can be restored if necessary and provides a baseline for comparison.
Wiring Audit and Photography: Carefully inspect the existing equipment wiring. Take clear, well-lit photos and create detailed, labeled diagrams (or use colored markers) to document the original connections. This prevents confusion later in the process.
Safety First: Confirm that the main power is secured and locked out before beginning any work.
The location of the central Induction Heating controller unit (the control board or electrical cabinet) directly impacts cable length, accessibility, and maintenance.
Determine Mounting Position: Select a cool, dry, and easily accessible spot for the Induction Heating controller enclosure. Ensure adequate ventilation.
Measure Wire Runs: Calculate the necessary length of the high-temperature power cable that will lead from the Induction Heating controller to the coil.
Stakeholder Consultation: Always review and confirm the placement and cable lengths with the facility's master electrician or plant foreman to ensure compliance with local electrical codes and operational workflow.
Accurate power measurement is fundamental to selecting the correct Induction Heating controller and coil for the application.
Initial Power Measurement: Accurately measure the power requirements of the existing system or the intended load. This data is critical for sizing the new Induction Heating controller and ensuring it operates within its safe range.
Documentation: Record the measured data and take photos of the original equipment nameplates. These records are vital for verification.
Installation Power Calculation: Use the measured data to confirm the final installation power. This step ensures the entire Induction Heating controller system is neither under- nor over-powered.
The preparation of the heating surface (often a barrel or pipe) is key to efficiency and accurate temperature control by the Induction Heating controller.
Measure and Cut Insulation: Measure the circumference of the barrel to determine the precise size needed for the insulation cotton. Proper insulation minimizes heat loss.
Form Preparation: Size the supporting insulation board (e.g., yellow wax board) that will hold the coil.
Probe Hole Placement: Carefully mark and drill the access hole for the temperature sensor (probe). The size and depth of this hole must be accurate to ensure the Induction Heating controller receives reliable temperature feedback for precise control.
Zone Definition: Clearly define and fix the boundaries of each temperature control zone if the system uses multiple heating sections.
The induction coil is the workhorse; its winding quality directly affects system efficiency and the performance of the Induction Heating controller.
High-Temperature Wire Length: Determine the exact length of the high-temperature wire required for the coil, accounting for the number of turns and spacing.
Aesthetic and Structural Winding: Wind the coil to ensure a neat and professional appearance. Crucially, maintain uniform pitch size control (the distance between turns) and ensure the winding is tight against the barrel.
Post-Winding Inductance Check: Use a suitable meter (paying close attention to its range) to measure the total inductance of the newly wound coil. This measurement is vital for ensuring compatibility and peak efficiency with the Induction Heating controller unit.
This is the integration phase where the Induction Heating controller is brought online.
Breaker and Meter Confirmation: Verify the rating and range of the existing circuit breaker and ammeter. If they are too small for the new load, they must be upgraded or replaced before proceeding.
Power-Up and Independent Testing: Connect the wiring and test each heating zone or component separately. Measure the voltage and current to confirm they are within the normal operating range specified by the Induction Heating controller manufacturer.
Troubleshooting: Address any electrical issues (voltage drops, current spikes) systematically. Once individual zones are stable, perform a full system test with the Induction Heating controller managing the entire load.
A successful installation concludes with meticulous cleanup and final documentation.
Site Cleanup: Completely clear and clean the installation area. Professionalism includes leaving the site in a pristine condition.
Operational Handover: Provide a complete operational check and training on the Induction Heating controller interface for the end-user or plant personnel.
By following these professional steps, you ensure the robust and efficient operation of your Induction Heating controller system, delivering energy savings and superior process control for years to come.
In order to ensure that the original production process is unchanged after the original equipment is switched to the electromagnetic heating coil, the original operating procedure is unchanged, and the performance difference between the two heating methods is designed. The electromagnetic heater has been reduced by about 30% of power usage, and is heated by electromagnetic heating. Power adjustment and power protection functions are designed on the controller. So the debugging process is quite simple, the user can debug according to the instructions.
| Name | Performance parameter |
| rated power | Three-phase 100KW |
| Rated input current | 120-150(A) |
| Rated output current | 240-260(A) |
| Rated voltage frequency | AC 380V/50Hz |
| Voltage adaptation range | constant power output at 300 ~ 400V |
| Adapt to ambient temperature | -20ºC~50ºC |
| Adapt to environmental humidity | ≤95% |
| Power adjustment range | 20% ~ 100% stepless adjustment(That is: adjustment between 0.5 ~ 100KW) |
| Heat conversion efficiency | ≥95% |
| Effective power | ≥98%(Can be customized according to user needs) |
| working frequency | 5~40KHz |
| Main circuit structure | Full bridge series resonance |
| Control System | The DSP-based high-speed automatic phase-locking tracking control system |
| Application mode | Open application platform |
| monitor | Programmable digital display |
| start time | <1S |
| Instantaneous overcurrent protection time | ≤2US |
| Power overload protection | 130% instantaneous protection |
| Soft start mode | Fully electrically isolated soft start heating/stop mode |
| RS485 communication | Modbus RTU standard communication protocol |
| Support PID adjustment power | Identify 0-5V input voltage |
| Support 0 ~ 1000 ºC load temperature detection | Accuracy up to ± 1 ºC |
| Adaptive coil parameters | Double 35 square line, length 35m, inductance 85 ~ 100uH |
| Coil to load distance(Thermal insulation thickness) | 20-25mm for circle, 15-20mm for the plane, 10-15mm for ellipse and within 10 mm for superellipse |
