One, Technical specifications of the 5KW electromagnetic heating control board:

Dimensions: 219*160*160 (Length*Width*Height)

2: Working Voltage: 220V

3: Power (Adjustable): 3500W-5000W

4: Load Inductance: 65±5Uh, approximately (11 meters - 12 meters)

5: Conversion Efficiency > 90%

6: Frequency of Operation: 20-25 kHz

Operating Temperature: -10°C to +50°C

8: Work Method: Continuous Heating

Surge Protection - +1500V

10: Anti-jamming Interference: 4000V

The installation distance from the electromagnetic induction coil to the heating element is 15-18mm (thickness after the thermal insulation cotton is tightly pressed).

Multiple coils are wound around the same heat source, with a distance between each coil greater than 6 centimeters.

II. Connection Instructions

1. Three indicator lights: "Power," "Operation," and "Fault." During normal operation, the "Power" and "Operation" lights are on, while the "Fault" light is off. When a circuit fault occurs, the "Fault" light blinks.

2. Power 220V is connected to the post labeled "Connect 220V Power Input" without distinction between the live wire and the neutral, simply plug in as desired.

3. The coil is connected to the two terminals "OUT1" and "OUT2"; the screws must be tightened securely.

4. The board is factory-set to operate as soon as it's powered on. At this point, there is a short circuit (black) inside the "Switch Control" socket. You can also gently remove the black short circuit from the "Switch Control" socket and insert one end of the two-core connection wire into the "Switch Control" socket. The other two connectors are connected to the normally open contacts of the temperature controller. Once connected, you can test and use the machine.

Section 3: Instructions and Precautions

1. Control Box Requirements: As the main controller is a high-voltage, high-current device, it should be installed within the control box during use and then connected to the heating coil, power supply, and temperature controller via insulated wires to prevent electric shock accidents caused by direct contact with live parts. Since the controller generates heat, the control box must be designed to allow air circulation for effective heat dissipation. For the 5KW component surface, an additional DC12V DC fan is added due to the need for heat dissipation from the choke coil. Please mount the fan on the two mounting posts on the board and plug the fan's connector into the FAN12V two-pin socket next to the relay on the board.

2. Heating Coil Requirements: As our company currently only provides the main control board to customers, this controller needs to be used in combination with other accessories such as heating coils. Different controllers are paired with different coils for various power ratings; for a 5KW system, it is recommended to use 10 square mm high-temperature wire. Typically, the coils are round and, when wrapped around the heating object, the inductance L is 65±5uH (measured using Victory's BICTOR6243+ inductance meter on the 2uH range, to be measured on the barrel, note: round coils are generally wound around 23 times, with different numbers of turns depending on the barrel diameter; this should be adjusted based on actual use.)

3. Heating Coil Winding: The heating coil is wound according to the specific requirements of the customer, ensuring the winding direction and parameters are set in alignment with the core. Maintain a distance of over 60mm between each coil and another.

4. Distance requirement for electromagnetic heating coil and heated metal object: The distance from the surface of the heating coil to the surface of the heated metal object should be appropriately adjusted based on the width of the coil. For a 5KW controller, the distance to the heated metal object should be adjusted according to the diameter of the pipe, with larger diameters requiring a shorter distance and smaller diameters requiring a longer distance. Typically, this is between 15-18mm. An overly short distance can cause the controller to overheat due to poor working characteristics, potentially leading to an explosion of the power tube; an overly long distance will gradually reduce the power and cannot be adjusted, which is due to the circuit's reverse voltage protection mechanism.

5. Connection Methods: This controller can be connected for use with power-on startup, or it can be controlled by the normally open contact of the temperature controller.

To power on and start using: Connect the 220V power supply to the controller's live and neutral terminals using insulating wires; connect the coil's leads to the controller's coil connection terminals (make sure they are securely connected). The motherboard is factory-set to start up and operate immediately upon power-on.

b. Operation of the normally open contact of the thermostat: Connect the 220V power supply to the controller's live and neutral terminals via the insulated wire; connect the leads of the coil to the controller's coil terminal ports (ensure a firm connection). Gently remove the short circuit from the "switch control" socket (black). Insert one end of the two-core connected wire into the "switch control" socket, and the other two plugs to the normally open contact of the thermostat. The connection is complete and the device can be tested for operation. Note: The thermostat's contacts must not be connected to the municipal power or any high voltage.

C. Operating Multiple Electromagnetic Heating Plates in Series: When it's necessary to control multiple plates to work and stop simultaneously with a single thermostat contact, first, identify one plate as the master board (choose any), then connect the "sub-board control" on the master board to the "voltage control" of another sub-board using a serial connection cable (a two-core wire with two 2-core plugs on each end). To connect more sub-boards, simply use the serial cable to link them in the same manner, that is, connect the "sub-board control" of one sub-board to the "voltage control" of another sub-board, and continue this pattern.

Note: The connection wires between the coil and the controller must be woven like a braid!

The electromagnetic heating system consists of two parts: the electromagnetic heating control board and the heating coil. The original power supply, which is temperature-controlled [output terminal of the heating output contactor (or solid-state relay)], is converted by the electromagnetic heating control board from industrial frequency AC power to a high-frequency AC power of 18-30 kHz through rectification, filtering, and inversion. This high-frequency AC power is then connected to the electromagnetic heating coil via a wiring harness, where it passes through insulating material to act on the cylinder, causing it to heat up internally. Alternatively, the power supply can be directly input into the electromagnetic heating control board, with the existing temperature controller used to control the electromagnetic heating control board.