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HS2500R2  Heating System

The HS2500R2 heating system provides fast and precise heating for a wide variety of applications.  Heating is flameless and non-contact utilizing a focused electromagnetic field.  A typical heating system, as shown below, consists of the HS2500R2 power supply, remote output transformer connected with a 6' long flexible power cable and a custom heating coil.  The HS2500R2 is available in two models.  The standard HS2500R2 features a basic control panel that includes a power control knob, KW output display and LED status lights.  It is often

used as par of a fixture or machine where the heater will be controlled with user supplied controls or a PLC.  The HS2500R2C model features a enhanced control panel that includes two digital timers with two power control knobs, KW display, on/offpushbuttons and LED status indicaator lights.  It is typically used for benchtop stand alone applications.  Some applications include insert pressing, diamond brazing, heat shrinking, carbide brazing, soldering, melting, annealing, epoxy and adhesive curing, and catheter tipping.

HS2500R2 Power Supply
Output
Transformer
Heating
Coil
Coolant
Input
6' Flexible Power
Cable Assembly
Part in Coil
To Heat
Optional Remote On/Off Pushbutton
Typical HS2500R2C Setup

General Specifications

  • 2500 watt water cooled power supply.

  • 200-240V 50/60hz 1ph power.

  • Output frequency 20-40 khz.

  • Compact, 16ga steel power supply enclosure.

  • Power Supply is 48#.  12.25"W x 14"H x 7"D

  • Easily fixtured remote output transformer.

  • Transformer is 3#. 6"L x 3"W x 3"H

  • Standard 6' long flexible power cable.

  • On/Off fast trip circuit breaker.

  • Integral coolant flow transducer to protect against overheating.

  • Power tracking circuitry delivers constant power even with plant voltage fluctuation.

  • Operates in resonance. No need to "ring up" to power.

  • Output verification circuit provides feedback to monitor heating cycle to cycle.

  • Fast acting semiconductor fuse to protect power semiconductor module.

  • 2 models. HS2500R2 & HS2500R2C.

  • HS2500R2 features standard control panel with KW display and power control knob.

  • HS2500R2C features dual timer/power control panel with KW display.

  • Bottom or rear flange mounting.

HS2500R2 Power Supply

The HS2500R2 induction power supply is the primary component of the system.  Its' function is to convert 50/60Hz line power to a high frequency, high amperage output and to deliver this power to the output transformer which, in combination with the heating coil, sets up a varying electromagnetic field that heats the part. 

The power supply is a 100% solid state AC/DC/AC inverter, operating at a resonant frequency of 20-40Khz.  The actual operating frequency is dependent on the design of the heating coil, the turns ratio of the output transformer and the internal capacitance of the power supply. The power supply along with the output transformer and heating heating coil requires water cooling. Coolant is supplied to fittings located on the side of the power supply and is verified by a coolant flow transducer with visible paddlewheel.

Power Cable

to Output

Transformer

Coolant Flow

Paddlewheel

Coolant In/Out

Fittings

Output Transformer for HS2500R2

2500 OT_edited.png

Transformer terminal

blocks with c'bores

for O rings

HS2500R2 Output Transformer

The output transformer is a special high frequency step down transformer that is used to match the heating coil to the power supply.  It connects to the power supply with a 6' long flexible power cable assembly that supplies both power connections and coolant tubing.  The heating coil attaches to the terminal blocks on the face of the transformer using 4 10-24 brass screws and washers.  The flexible cable allows the transformer and heating coil to be located remotely from the power supply and attached to any processing fixture as required.

The output transformers for the HS2500R2 system are available with turns ratios of 7:1, 10:1 and 14:1.  These ratios enable the use of a wide range of heating coils.  In general, small coils, e.g. a 0.50" diameter 2 turn coil, would use the 14:1 transformer.  The 7:1 ratio transformer would be used for larger coils, e.g. 3 or 4" diameter.  The 10:1 transformer covers the mid range of coils and is used in most applications.

The HS2500R2 output transformer is 3"W x 3 1/2"H x 6"L and weighs 4 lbs.

Heating Coil for HS2500R2

The heating coil focuses the electromagnetic field onto the area of the part that is to be heated.  The coil attaches to the terminal blocks using 4 10-24 brass screws.  Heating coils are manufactured from copper tubing and are water cooled and stay relatively cooleven while heating hot parts.  Coolant flows through the output transformer and into the coil.  Coolant leakage is prevented by the O rings mounted in the c'bore of the transformer terminal blocks.

More information on heating coils can be found in the coils and inductors section.

Typical Heating Coil for HS2500R2

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