5T Intemediate Frequency Furnace

郭珂/Guoke +86 132 9904 2234 Skype: guoke896884090
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guoke1207@hotmail.com
5T
INTERMEDIATE FREQUENCY WITHOUT CORE INDUCTION
MELT COOKER TECHNOLOGY SCHEME
Summarize:
In this scheme, a set of equipment consist of two electric cooker
bodies, an intermediate frequency electrical source, a hydraulic pressure
equipment. A intermediate frequency electrical source supplies powers
for two electric cookers in which one are melting ,the other are standby.
Ⅰ. Technique parameter
item Unit data
Electric cookers parameter
Rating capacity t 5
Maximum capacity t 6
maximum working temperature ℃ 1750
electric parameter
transformer capacity KVA 3500
transformer first voltage KV 10
transformer second voltage V 750、750
intermediate frequency
electrical source
rating power
KW 3000
intermediate frequency
electrical source maximum
output voltage
V 1500
working frequency Hz 250
transforming frequency % 98
start-up success frequency % 100
complex parameter
fusion ratio(temperature
was raised to 1600 ℃)
t/h 4.8
power cost of fusion
(temperature was raised
KW·h/t 600

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to 1600 ℃)
working noises db =85
hydraulic pressure system
station capacity L 500
working pressure Mpa 13
hydraulic pressure medium grease
cooling water system
flow quantity t/h 144
water supply pressure Mpa 0.25-0.35
input water temperature ℃ 5-35
output water temperature ℃ ＜55
Ⅱ. Technical criterion and working condition of equipment
The parts of the equipment accord corresponding technical criterion listed
behind.
1. GBl0067.3— 88 the basic technical condition of
galvanothermy equipment— induction galvanothermy equipment.
2. GBl0063.3— 88 the experiment method of galvanothermy
equipment— non-core induction melting cooker.
3. GB5959.3-88 the safety of galvanothermy equipment— special
require on inductive and conductive heater and inductive melting
equipment.
4. JB4086-85 intermediate frequency non-core induction
heat-up use the technical condition of the equipments controlled by
electricity.
5. JB ／ T4280— 93 intermediate frequency non-core induction
cooker.
6. GB／T14549-93 the quality of power— the performance and

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technical parameter of the resonance-wave equipment used in electricity
network reach the regulation of technology specification book.
Ⅲ. Normal working condition of the equipment listing behind
1. Environment
a. Altitude is below 1000 m.
b. Surroundings temperature is between 5 ℃ and 40℃.
c. Relative humidity is not above 90% (25℃).
d. No conductive dust, explosive gas and causticity gas which can
damage metal and insulation.
e. No obvious vibration and jounce.
2. Power supply demand
a. Power supply voltage in main circuit is 1OKV, fluctuation is less
5% and three phase imbalance is less 5%.
b. Power supply voltage in control system is 220 V and fluctuation is
less 5%.
c. Power supply voltage in main circuit and control system must be
sine wave whose shape aberration is less 10%.
3. The demand of cooling water in outside cycle
a. Overall rigidity is less 60 mg equal quantity per liter.
b. dissolutive solid substance < 300 mg／L.
c. PH 7— 8.5.
d. suspension solid substance < lOmg／L.

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e. conductance rate <500µs／cm.
f. input water temperature =35℃.
Ⅳ. Technique explanation of electric parts
The electric parts of equipments consist of
electrical source commutation transformer,
Intermediate frequency electrical source cabinet,
compensation capacitor groups, and high voltage
switch cabinet.
1. Electrical source transformer
The electrical source transformer is used to
drop 11KV high voltage electricity in electric network to one which can
fit Intermediate frequency electrical source. The equipment adopts special
commutation transformers which self-cooling dipped in oil.
1.1 commutation transformer used for fusion:
rating capacity 3500 KVA
the first voltage 10 KV,
the second voltage 750 V。
impedance in short circuit between 6％ and 8％
non-load switch installed on the high voltage side and used to
regulate voltage by hand can adjust on three stages -5％，0，+5％.

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1.2. Intermediate frequency
electrical source
The type of intermediate
frequency electrical source in the
electric cooker is KGPS -3000
/0.25.
Circuit principle drawing is listed
below.
2. Intermediate frequency electrical source main loop principle chart
2.1 Commutate part control silicon adopt up to date fold installed
radiator groupware as following chart
This kind of install mode is more convenience and science to remove
and install control silicon .When change control silicon, only loosen tip
tighten bolt, you can change anyone control silicon component in
groupware. Radiator component has scale which can consult when fasten,
and this guarantee right pressure during control silicon and radiator.
Moreover, this kind of installs mode minish control silicon groupware

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volume, which makes operation room in electric cabinet bigger.
2.2 Great capacity direct current sieve wave reactor
Sieve wave reactor is very important for solid electrical source，it has
two function ，the one is to make output current smooth and stable；the
other is when athwart change control silicon short circuit，it circumscribe
short circuit increase rate and the biggest short circuit 。If sieve wave
reactor parameter design inconsequence，iron core material is not good or
production techniques do not pass the test ，all those may influence
reliability of intermediate frequency electrical source。
2.3 Athwart change circuit adopt great speediness control silicon
To guarantee athwart change circuit reliability，athwart change control
silicon adopt two big capacity KK silicon in series
2.4. Adopt series-parallel connection compensate circuitry to minish
wastage of transmit electricity circuitry
To minish intermediate frequency transmit electricity circuitry wastage,
athwart change circuit compensate capacitor adopt series-parallel
connection, as follows:
C1
L
Intermediate C2
Frequency output
This kind connection can enhance cooker output voltage twice as

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athwart change circuit. And at the same output power output electrical
current become only 50% as before, which make intermediate frequency
transmit circuitry wastage minish to 1/4.
2.5 Main circuit parameter and component selection foundation
When adopt 6 pulse wave rectifiers, commutate control silicon
average electrical current can be calculated according to the following
formula:
Ikpmax=Id max／2.72
Athwart change control silicon average electrical current can be calculate
according to the following formula:
Ikkmax=0.45XIdmax
Choose control silicon standard and select
2.6 Characteristic of intermediate frequency electrical source
2.6.1 Control system total numeric, without continue electricity control
Control system adopt ISP program logical array module to
integration control. Its core apparatus adopt high performance, high
density ,great standard special ASTC-2 integration circuit ,which is made
in USA, and this makes all signal
dispose and correspondence
operation carry out automatism
according to program. Replace all
kind of continue electricity control

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with data control system to finish the function.
2.6.2 Unique browse frequency model startup mode has 100% startup
succeed rate.
Athwart change part adopt browse frequency zero pressure soft
startup ，which has better performance than common zero pressure soft
startup circuit。Browse frequency model startup process as following：
before startup，touch off athwart change
crystal brake pipe with stimulating signal whose frequency is higher than
slot route syntony， moreover control stimulate signal frequency to
browse from high to low，when the frequency is near slot route syntony，
intermediate frequency voltage is set up .To prevent intermediate
frequency voltage startup failure occasionally，our company design
automatism startup circuit，ensure 100% startup succeed rate，moreover ，
its response time is very short，it only takes less than 500 MSEL to finish
a automatism startup.
2.6.3 Adjuster with quick respond identity
Our company have design particular adjuster in control circuitry
whose responding time is very short, the adjuster is completely fit for the
use demand of speediness respond in the condition of the load break of
intermediate power supply.
2.6.4 Electrical source constant power is output to ensure supernal power

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factor
The impedance adjuster is devised especially which can inspect the
change of the impedance and deliver it to circuit interior processing
figure operation and adjust automatically matching load to make
intermediate frequency power supply reach constant power. At the same
time, the running power factor of the whole set equipment reaches above
0.93 because of using impedance adjuster in the course of melting. The
relation graph of constant power intermediate frequency voltage US and
its corresponding power factor φcos is given in following drawing.
COS?
0
1050V 1300V
Us
(Constant power intermediate frequency voltage and its
corresponding power factor connection graph)
2．6．5 Having outstanding anti-striking load capacity
There leave enough space in choosing main apparatus in system.，
which guarantee each apparatus outstanding anti-striking capacity。Our
firm provides especial device in control part of system on software, and

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this makes system running more stationary and reliable and prevent
monocrystalline silicon efficiently from damage of electric impulse while
adding material .Thus, the equipment’s good capability of impulsion
resistance is ensured and the equipment can run on the safe side in long
period.
2.6.6 Perfect and reliable protection function
Such protection measure of overflow, overload, over press，phase
shortage, lack of voltage of controllable power, too low cooling water
pressure, too high temperature of cooling water and too low water flux
are provided in this controlling circuitry. These protection functions are
analyzed and realized by ASIC-2 integrate circuit, which ensures the
sensitivity and reliability of those protection function. This system is
water cooling equipment, real time inspection to cooling water on many
point has to be carried out for equipment runs on the safe side. Our firm
devises a set of characteristic inspect instrument for a special purpose aim
at importance of water inspection. Two temperature inspection points is
set on each controllable silicon, and the same points is set on each
syntonic capacitor and every induction loop. This makes each part of
water cooling of this system be inspected at real time. It is impossible to
damage part of apparatus which have too high water temperature on one
point.
2.6.7 Advanced auto identify function of phase order

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A auto identify circuit of phase order is contained in controllable
system, which makes system need not install synchronic transformation
and excuse phase order modulation and the job to synchronize while
debugging and maintaining.
2.6.8 abundant outside controllable interface
It is set on the equipment that Out/In transformation, Auto/Hand
control switch and their interface, which can realize auto controlment
from long distance conveniently. And outside temperature ring
controllable interface is set to combine infrared temperature inspect
instrument and temperature auto controlling system, which can realize the
auto modulation of program enactment temperature rising to output
power of electrical source and makes final calefaction temperature of
steel tube reach anticipated temperature.
2.6.9 Light isolation impulse output
In controlling system, there are double isolation measures in
springing impulse between controlling board to controlling pole of
controllable silicon. Light isolation apparatus with its pressure endurance
over 2500V is used on controlling board to insulate springing impulse
from light or electricity, and transformer groupware with its pressure
endurance grade of over 3000V is used on impulse transformer. Even
though controllable silicon is stroked out because of over pressure, it has
little influence on controlling system.

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2.6.10 Simple and convenient to debug and maintain
The major parameters’settings on controlling board are finished by
internal circuit of controlling board. There are only six potentiometer
parameters’settings which can be modulated by user. So the controlling
board is perfectly universal and reciprocates, and it is simple and
convenient to debug and maintain.
2.7 Cooker leaking protection and earthling alarm brake function
A special detector of cooker liner’s thickness is set on controlling
system. The working theory is to verdict the perfection of cooker liner
through leaking current between inductive loops and charging.
Because leaking current must amply while cooker liner becomes thin.
Alarm current of cooker liner thickness detector can be modulated.
Appropriate alarm current must be modulated gradually while it is being
used according to different size of cooker and different material of cooker
line.
Cooker liner thickness detector cann’t runs correctly 100 percent. It
can only offer reference of judging cooker liner thickness.
The cooker liner thickness detector is connected between side pole
and bottom pole directly.
2.8 Compensating capacitor
groups

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To minish waste of big current circuit, compensating capacitor groups
are set on the position next to electric cooker in basement as possible as
they can.. All capacitor are new innoxious water cooling intermediate
frequency big capacity capacitors, which have such merit as big capacity
of each one, low waste of medium and small area of containing ground.
Digital temperature inspecting component is installed on each capacitor,
which can auto stop intermediate frequency electric source through
working temperature inspected by especial temperature inspection
appearance developed by our firm while temperature is over high and
alarm signal is come up.
Capacitor groups all use big section water cooling copper arrange.
Working temperature of copper arranges must not beyond C0
45 to cut
down transmission waste of parallel connecting syntonic circuit.
Five．Part of electric cooker
It contains electric cooker body, water cooling cable, high fire
endurance pastern, speedy extrusion equipment of cooker liner and
copper arrange of main circuit.
1. cooker body
Cooker body contains induction loop, magnetic yoke, cooker frame,
leaning oil jar and cooker cover.
1.1 Inductive loop

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The inductive loop is circled by 99.99 percent rectangle copper cube.
Insulation on the inductive loop surface is smeared a flat of high strength
insulated colophony using static gushing craftwork, whose insulation can
endure voltage more than 6000V.
Inductive loop is fixed up by lists of bolts sealed around its
circumference and insulated supporting bar. After loop is fixed up, its
error of circle distance is no more than 2mm.
Copper water cooling circles are set on the top and the bottom of
inductive loop to make cooker liner material is heated evenly in axial
direction and to prolong the working life of cooker liner.
On the outside surface of inductive loop, couples of temperature
explorer stationeries are welded on waterway subsection to fix up
temperature measure component. While one of water way is jammed,
alarm is given off immediately and the intermediate frequency electric
source ceases automatically.
1.2 Magnetic yoke
The magnetic yoke is made up of cold rolled silicon and steel of
high magnetism transmit rate. The thickness of silicon and steel is o.3mm.
Profile modeling configuration is used in the magnetic yoke, whose
internal arc face radian is equal to outer circle’s radian of inductive loop.
This make the magnetic yoke can cling to outer side of inductive loop,
and inhibit the magnetic field emanated out by loop to decrease magnetic

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block of outer magnetic circuit.
The magnetic yoke is hold by stainless steel plates on both sides and
stainless steel clamps. It is weld to root. Cooling water cubes are weld on
the stainless steel plates on both sides to cool magnetic yoke. The cooling
water cube can endure 0.45Mpa water pressure and has no leaking out in
15min.
After the magnetic yokes are installed completely, the camber is no
more than 4mm, the warp of theoretical center line and practical center
line are no more than 3mm.
1.3 cooker frames
The cooker frames divide into active part and stationary part.
Active cooker frame is used to install inductive loop and magnetic yoke,
which is weld by profiled bar and armor plate and utilize framework
configuration. The framework has removable cover board, which is
convenient for examine and repair. Deepen armor plates are used on the
operation flat roof on the top of cooker frame to enhance the intensity and
bearing ability of the cooker frame.
There is a cooker cover on the top of active cooker frame, and
hydraulic pressure driving fashion is used. The ascendance and rotation
of it are accomplished by two ole jars to ensure cooker cover to run in
gear and reliably
The stationary cooker frame is set on the groundsill to hold the active

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cooker frame. There are leaning rolling axes connected to the cooker
frame over the stationary cooker frame, which can make active cooker
frame rotate 0
95 ahead. A fast cutting valve which can prevent breaking
and limit velocity is set on the bottom of the leaning cooker oil jar. In the
course of inclining cooker, if the ole jar is broken, the cutting valve which
can prevent breaking and limit velocity will act to cut off the returning oil
circuit of the oil jar and make the electric cooker state on the original
position.
There is a very big safety factor remained in the period of dividing.
This ensures that the cooker frame has enough rigidity and run placidly
when it bears the most loads.
Induction winding and charging parameter:
Induction winding and charging parameter is optimize designed by
special computer ，which guarantee the best electromagnetism coupling
efficiency at same capacity. Considering electric cooker need over take,
we design that rating capacity is bigger than standard .Only that can
guarantee charging liquid surface would not exceed water-cooling circle
upper surface at the biggest charging capacity. Since the part above
water-cooling circle is not cooled, if the part touches charging for long
time, it will produce high temperature, which makes cooker liner craze at
water-cooling circle.
2. water-cooling cable

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water-cooling cable joint adopt cool pressure molding techniques to
press with copper wind line，which joint fastness，contact resistance
small，do not damnify copper wind line. The single tie-in and copper line
can endure more than 8t pull
Water-cooling cable outer bushing adopt special hinder-burning rubber
pipe, which is not flammability. Intension is good，which can endure
0.45Mpa water pressure.，no leak，no break。
material， which smear among circumference and inside induce
winding ，has following function：
（1）It makes induce winding whole，reduce vibration and noises when
work.
(2)when charging leak ，it can protect induce winding.
(3)It makes for pulling cooker liner.
4. Pulling cooker liner rapidly equipment
Pulling cooker liner rapidly equipment，which include tip push block，
tip push oil jar and operation framework, is used for getting rid of old
ones rapidly.
Tip push block，under cooker liner，is linked with tip push oil jar
through the bottom of cooker. when pushing out old cooker liner ，turn
the electric cooker 90 degree，fix tip push oil jar with bolt and joint flange.
Operate handy valve to press oil jar ，then old cooker liner is pushed out .

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Six .hydraulic pressure
Including hydraulic pressure pumping station and leaning cooker
manipulation platform:
Hydraulic pressure pumping station is used for supplying power to
leaning cooker, cooker lip drive oil jar, cooker liner push oil jar. Pumping
station rating work pressure is 11Mpa. Hydraulic pressure medium is
hydraulic pressure oil.
Leaning cooker manipulation platform is used for controlling the
cooker to lean, turn round, switching cooker lip and pushing cooker
liner。 It adopt handle valve, act placidity, no impulsion.
All hydraulic pressure components adopt joint venture high quality
product.
Seven: cooling water system
Cooling water system adopts cooling tower of FBNL close type or
FKHL open type whose concrete parameter select may refer to the
data of sample production.
Eight: installation and base map
The installation of the facility and base map are showed in attached
drawing.
Nine: technique datum and drawing

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We supply following technique datum when the equipment leave
factory.
1. machine part
It includes electric cooker exterior drawing, base drawing, plane lay
drawing, land build demand, the data of flat roof and cooling water
system, easy damage piece drawing.
Equipment fixing and debug instructor, the guidance book of use and
maintenance about electric cooker.
Hydraulic pressure principle drawing, the guidance book of the
Hydraulic pressure system.
The guidance book of the water system.
2. electric part
It includes the principle drawing of the electric and circuit, exterior
wiring diagram, electric component table, the guidance book of
intermediate frequency power supply, the guidance book of control
system malfunction inspection exclusion.
Ten: Equipment beforehand validate and training
When all the equipment manufacture is over, we will invite the buyer
technician to the equipment manufacture factory, take part in the
equipment beforehand check , accept and training.
1. beforehand check and accept content:

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(1) commonly inspection
(2) security inspection
(3) the cooker assemble dimension examination
(4) inductorium manufacture quality examination and insulation,
pressure endurance experimentation
(5) measurement the electric gap between inductorium and cooker
shell
(6) measurement insulated resistance between inductorium and cooker
shell
(7) measurement insulated resistance between inductorium and
magnetism yoke
(8) intermediate frequency cooker insulated, pressure endurance test
(9) pressure test of hydraulic pressure system
(10) leaning cooker manipulate test of leaning cooker transmission
framework
(11) induction winding hydraulic pressure test
(12) electric linkage and spillage cooker alarming equipment
experiment
(13) electric malfunction display, monitor, alarm etc protect functional
inspection
(14) match inspection, including model, standard, up to grade certificate
leaving factory

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(15) supply good range, technique document integrality test
2. Training
(1) The seller supply user the following technical training the equipment
installation training
(2) Electric control design principle training.(Including: electric design
protection, inspection, malfunction display)
(3) Equipment maintains and daily maintains work training
(4) Equipment ordinary malfunction and special malfunction elimination
training
3. All the beforehand check and accept item and test data should be got
when two sides attend and signature, supply user the data at the same
time.
4. Only when all the check work is over and two sides agree to sign it, the
seller can package and consignment the equipment
Twelve install, debug and the final check and accept.
Eleven: Installation, Debug and final check and accept.
1. When the equipment installation is over, our company will send respect
specialist install spot to check the installation and precision, and then
debug the equipment
2. The seller specialist will train the user employee to handle and repair
the equipment at the spot

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3. The equipment final check and accept should be held at user spot, the
item including:
(1) all the check item and completely safety check;
(2) Induce cooker heat preservation power parameter measurement;
(3) Induce cooker heat preservation power measurement，temperature
rising productivity measurement
(4) Induce cooker electricity consume and melt rate measurement
(5) Refrigeration medium temperature rising measurement
(6) The cooker component temperature measurement
(7) Charging temperature measurement
(8) Noises measurement
(9) Check after heat condition experiment
(10) Alarm system dependability and sensitive degree examination;
(11) According to technical demand clausal validate
When all the item have been checked, tested, write out the final
examination report, both sides get agreement, the contract get into effect
Twelve: product quality control measure
1. Our company is strictly according to ISO9001 quality standard at
quality control, set up a completely quality system document and get
across quality authentication. When we select the oral material and in
addition fitting, we set up a whole and up to grade provider, to be sure the

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quality of oral material.
2. In the process of the production, every spare part has quality
responsibility track card, which record every step responsibility and the
final check .to the pivotal part such as inductor ,magnetism yoke etc, we
have special technique regulations, which ensure that only the up to grade
part from last working procedure can get across the next.
3. We will checkout the product before leaving factory. Which include
appearance examination, mechanism measurement, induce winding
insulation checkout, bear the press and water trial. The lean movement
of .electric cooker examination cooker lid rise drop and circumrotate
examination.
4. Hydraulic pressure system check-out and each intermediate frequency
electrical source parameter examination ,when all the examination is up
to grade ,the checkout will fill product checkout certificate, and record all
kinds of examine data ,which guarantee product quality can trace back
Thirteen: product quality guarantee
1. The electric cooker facility is made up with bran-new, high–quality
material which can compare with equipment technique standard
explanation book; all substantiality facets are fitted with equipment
technical standard explaination book.
2. All the main outer fitting of equipment have product check-out

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certification.
3. We guarantee to keep the electric cooker equipment in good repair for
twelve month since the final check-out. During the guarantee period,
all the malfunction caused by the equipment manufacture badness or
low quality of outer fitting, we will repair and change relevant part.
4. We provide 24 hour respond service .we will send to serve the user
during 24 hour in the country ,to abroad the time should take
transaction go abroad procedure into account depend on the
government work efficiency.
5. To be certain stability of production, we provide customers spare part
at benefit price which is lower than market price at same time.

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The whole equipment sets includes
number device name model quantity
1
Frequency thyristor
converter KGPS
KGPS-3000KW/0.25KHz 1
2 Link copper
Between the power supply
to the capacitor
1
3 Capacitor bank 0.25KHz 1
4 Water-cooling cable set 2
5
Induction melting
assembled unit
GWJ-5.0t 2
6 Hydraulic System 1
7 Crucible mould 2
8 Water Distributor 2
9 Operation Platform 1
10 Furnace leak alarm system 1
11 Lining ejector 1

5T Intemediate Frequency Furnace

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