Smart Power™
Induction Heating Innovation by Ultraflex
Ultraflex SmartPower™ Compac Systems are a breakthrough innovation in induction heating technology, featuring the Direct Digital Step™ control algorithm and a unique configurable modular approach.
Configurable and field upgradeable power supplies with output power from 50kW to 400kW.
Wide output frequency range – two ranges available from 6kHz to 60kHz and from 40kHz to 200kHz.
Zero downtime can be achieved if an additional module (N+1) is installed in the system.
The latest SiC transistor technology and proprietary digital control algorithms ensure optimal performance and maximum efficiency in a wide frequency range.
Ultra-flexible, wide range of load impedance matching by utilizing multiple transformer ratios and configurable capacitor banks.
Configurable to work with a single or multiple, independently controlled RF outputs from one cabinet.
Can operate with optional heat stations allowing the load coils to be placed remotely.
Durable and reliable design with built-in tuning, safety, and diagnostics features.
Learn more about the Benefits of SmartPower and the Benefits of Modular Induction Heating Systems.
OPERATION
- Precise power control from 0 to 100% of rated power
- Output regulation: Voltage, Power, Current
- Parameter Monitoring: Current, DC Volts, Output Volts, Power, Frequency
- RF Amplifier modules operating in a wide frequency range
(6kHz – 200kHz)
- Control modes: Automatic, Remote or Local control
- Automatic frequency scanning and load tuning
- Fast dynamic response and ramp-up time for short heating cycles
- Variable ratio transformer for matching to a wide range of loads and coils
USER INTERFACE
- Industrial control panel – 12” LCD touch, full color
- Advanced and intuitive user interface
- Multiple heating programs and profiles for automatic process control
- High accuracy cycle-by-cycle energy monitoring
- Built-in temperature control and monitoring features – optional
- Data logging of process and operating parameters
CONTROL
- 0-10V or 4-20mA external control and remote Start/Stop operation
- Ethernet and USB connectivity for firmware upgrades and diagnostics
- RS485 (MODBUS) serial interface for remote control and monitoring
| USP-C-100 | USP-C-200 | USP-C-400 | USP-CD-100 | |||||
| Description | Single Output Full Rack | Dual Output Full Rack | Quad Output Full Rack | Single Output Double Rack | ||||
| Number of PA Modules | 2 – 8 | 2 – 8 | 2 – 8 | 10 – 16 | ||||
| RF Outputs | 1 | 2 | 4 | 1 | ||||
| Power Amplifier Type | MF 25 / 60 | WF 25 / 200 | MF 25 / 60 | WF 25 / 200 | MF 25 / 60 | WF 25 / 200 | MF 25 / 60 | WF 25 / 200 |
| Frequency Range | 6-60 kHz | 40-200 kHz | 6-60 kHz | 40-200 kHz | 6-60 kHz | 40-200 kHz | 6-60 kHz | 40-200 kHz |
| Output Power Range | 50 kW (2 x 25 kW Modules) to 200 kW (8 x 25 kW Modules) | 50 kW (2 x 25 kW Modules) to 200 kW (8 x 25 kW Modules) | 50 kW (2 x 25 kW Modules) to 200 kW (8 x 25 kW Modules) | 250 kW (10 x 25 kW Modules) to 400 kW (16 x 25 kW Modules) | ||||
| AC Line, VAC 3-phase (50/60Hz) | 380 / 480 ± 10% | 380 / 480 ± 10% | 380 / 480 ± 10% | 380 / 480 ± 10% | ||||
| Dimensions Inch (mm) WxDxH | 23.6” x 28.3” x 72” (600 x 720 x 1820) | 23.6” x 28.3” x 72” (600 x 720 x 1820) | 23.6” x 28.3” x 72” (600 x 720 x 1820) | 47.2” x 28.3” x 72” (1200 x 720 x 1820) | ||||
| Weight Lb (kg) | 400-660 (180-300) | 400-660 (180-300) | 400-660 (180-300) | 400-660 (180-300) | ||||
| PA Modules Installed | PA1 | PA2 | PA3 | PA4 | PA5 | PA6 | PA7 | PA8 | Voltage Range |
| Input Current maximum [A] (RMS per Phase) | 34.7 | 69.4 | 104.1 | 138.8 | 173.5 | 208.3 | 243.0 | 277.7 | min 380V-10% |
| Input Current maximum [A] (RMS per Phase) | 31.5 | 62.9 | 94.4 | 125.9 | 157.4 | 188.8 | 220.3 | 251.8 | max 480V+10% |
| HSP-50 M | HSP-100 M | HSP-200 M | HSP-50 W | HSP-100 W | HSP-200 W | HSP-400 W | |
| Output Power Range | 40 – 50 kW | 50 – 100 kW | 100 – 200 kW | 50 kW | 50 – 100 kW | 100 – 200 kW | 400 kW |
| Frequency Range | 6 – 60 kHz | 10 – 60 kHz | 6 – 60 kHz | 40 – 200 kHz | 40 – 200 kHz | 40 – 200 kHz | 50 – 150 kHz |
| Dimensions Inch (mm) WxDxH | 15” x 24,5” x 19,1” (382 x 624 x 485) | 15” x 24,5” x 19,1” (382 x 624 x 485) | 22,9” x 26,5” x 19,1” (582 x 673 x 485) | 15” x 24,5” x 19,1” (382 x 624 x 485) | 15” x 24,5” x 19,1” (382 x 624 x 485) | 22,9” x 26,5” x 19,1” (582 x 673 x 485) | 16,5” x 32,3” x 19,1” (420 x 820 x 485) |
| Weight Lb (kg) | 176 (80) | 200 (90) | 215 (98) | 176 (80) | 200 (90) | 215 (98) | 198 (90) |
- Configure your power and frequency range
- Multiple outputs in one system
- Upgrade your power as you need it
- Zero down-time operation
- Ultra flexible performance
- Latest SiC transistor technology
- Energy efficient and compact
- Low maintenance cost
Common questions about the Smart Power Series induction heating power supplies.
What is the frequency range of the Smart Power series?
The Smart Power Series operates from 5 kHz to 200 kHz. This wide range covers most industrial induction heating applications — from deep-penetration heating at low frequencies to surface heating and soldering at higher frequencies. The system automatically tunes to the optimal frequency for your coil and workpiece combination.
What external control options are available?
The Smart Power Series supports 0–10V analog input, 4–20mA current loop input, and remote Start/Stop operation. These standard industrial signal types enable seamless integration with PLCs, SCADA systems, and custom automation controllers for fully automated production line operation.
Can firmware be updated on site?
Yes. The Smart Power Series includes a USB port on the Control Panel for quick on-site firmware updates. This allows you to install the latest software improvements, new features, and performance optimizations without returning the unit to the factory or scheduling a service visit.
What transistor technology does the Smart Power use?
The Smart Power Series uses the latest Silicon Carbide (SiC) transistor technology. SiC transistors offer higher efficiency, lower switching losses, and better thermal performance compared to traditional IGBT designs. This results in a more compact power supply with improved energy efficiency and longer component life.
What is the output power range of the Smart Power series?
The Smart Power Series starts at 50 kW in the Single Output Full Rack configuration and scales up to 400 kW in the Single Output Double Rack system. The modular PA (Power Amplifier) design allows you to configure the system to your exact power requirements and expand capacity later if needed.
How many PA Modules can the Single Output Full Rack handle?
The Single Output Full Rack system accepts a minimum of two PA Modules and a maximum of eight. Each module adds incremental power capacity, so you can start with fewer modules and scale up as your production requirements grow — without replacing the entire system.
What are the cooling water requirements?
The Smart Power Series requires water cooling for the power supply and heat station. Minimum flow and pressure requirements depend on the specific configuration and number of PA Modules installed. We recommend using deionized or distilled water to protect internal components. See our water quality recommendations for detailed guidance.
PICTURES
Ready to Get Started with SmartPower™?
Download the full datasheet for detailed specifications, or let our application engineers help you find the ideal configuration for your heating process.
