Compact Billet Heaters KSO series up to 630 kW

Similar to the series SOP models, series KSO compact medium-frequency heaters are designed for the induction heating of steel billets with a circular or square cross-section up to forging temperatures. However the thyristor frequency converter is mounted inside the equipment so the entire unit is self-contained. Some obvious advantages of placing the frequency converter inside the heater are:

less floor space needed
lower construction costs (no cable ducts)
faster and cheaper installation at your facility
energy loss from mid-frequency cabling from an external converter is eliminated

The heaters consist of three modules – feeding, heating and delivery. If the customer so desires, the heater can be optionally equipped with a automatic hot billet sorter.

Heater KSO 250/10-A30

Basic technical specifications

Output series		160 kW	250 kW	400 kW	500 kW	630 kW
Heated Material		Magnetic Steel
Billet Dimensions	Ø D, square (one side) [mm]	15 - 60	20 - 80	30 - 100	30 - 120	50 - 130
Billet Dimensions	Lenght l [mm]	1,2D-300	1,2 D - 500
Max. Temperature Limit [°C]		1250
Maximum Process Capacity [kg/h]		360	625	1020	1300	1600
Output [kW]		160	250	400	500	630
Frequency [kHz]		4 - 10	2 - 6	1,5 - 4	1 - 3	0,5 - 1,5
Input Voltage from Transformer [V]		3 x 300	3 x 340	3 x 400
Energy Consumption [kVA]		200	315	480	600	800
Cooling Water Consumption [m³/h]		4	6,5	7,5	9,5	12

Heater control is handled by a programmable logic controller (PLC), available either as an Allen-Bradley or Siemens-based system (depending on the customers requirements). The temperature of every heated billet is monitored by a non-contact temperature sensor and these temperature values can then be stored in the PLC memory, along with its time/date stamp. System control is performed via an interactive display panel along with push-button interfaces all connected to the central communication board. Heater settings (required temperature, output, temperature limits, employee code, etc.), are legibly displayed onto the screen. Any system faults are also communicated to the operator thru this display.

Control box installed with a PanelView® interface display by Allen-Bradley™

Control box showing SIEMENS™ Simatic™ HMI interface panel

Heating module

Heating module contains:

MF capacitors
Cooling water circuit (placed on the right or left side)
Busbars (water-cooled)
Control modules and wiring for the heater and converters
Main circuit breaker
Thyristor frequency converter

MF Capacitors

Thyristor Frequency Converter

Inductor

The inductor is typically placed on the top of the equipment. New mid-frequency input connectors and cooling-loop quick-connectors help with quick inductor changeouts when necessary. We can design inductors with a square or circular heating chamber. The inductor dimensions are available in range from Model series': 20, 25, 30, 45, 60, 80, 100, 120, and 130. Of course, inductors of other dimensions have been, and can be, designed, built and delivered exactly to the customer's specifications.