Smart Power™ MEGA
UltraFlex SmartPower™ MEGA System is a breakthrough innovation in induction heating and melting technology, featuring the patented Direct Digital Step™ control algorithm and a unique configurable modular approach.
MEGA can be equipped or field upgraded to have up to four independently controlled coils or furnaces from one cabinet. Each output can be configured to deliver power from 64 kW to 1 MW in a 3 kHz to 30 kHz frequency range. The latest SiC MOSFET switching technology and innovative digital control algorithms ensure optimal performance and maximum energy efficiency.
The system can achieve an ultra-flexible wide range of load impedance matching by utilizing multiple auto-switchable transformer ratios.
Quick replacement or disabling of failed power modules ensures easy service, maintenance, and zero downtime.
OPERATION
- Precise power control from 0 to 100% of rated power
- Output regulation: Power or Current
- Parameter Monitoring: Current, DC Volts, Output Volts, Power, Frequency
- Control modes: Automatic, Remote, or Local control
- Automatic frequency scanning and load tuning
- Variable ratio transformer for matching to a wide range of loads and coils
- Durable and reliable design with built-in safety, and diagnostics features
USER INTERFACE
- 5” LCD touchscreen control panels, full color
- Advanced and intuitive user interface
- Multiple heating or melting programs and profiles for automatic process control
- High-accuracy heating/melting cycle energy monitoring
- Built-in temperature control and monitoring features – optional
CONTROL AND PROTECTIONS
- 0-10V or 4-20mA external control and remote Start/Stop operation
- RS485 (MODBUS) serial interface for remote control and monitoring
- Built-in safety and Ground fault protection circuits
SmartPower™ MEGA gives manufacturers the flexibility of multiple induction systems in one compact platform.
Scale power as your production grows
Start with the power you need now, then add modules and outputs later as demand increases. This makes SmartPower™ MEGA a stronger fit for growing operations, staged capital spending, and applications that may expand over time.
Run more processes from one cabinet
Up to four independently controlled outputs can be configured in a single system. Each output can be optimized for a different coil, furnace, load size, or process step, which gives you more flexibility with less equipment on the floor.
Reduce downtime and simplify service
The modular design makes service easier, reduces spare-parts complexity, and helps keep production running. With independent output operation and optional redundant RF modules, the system can continue operating even when a module or output requires service.
Stay efficient with difficult, changing loads
SmartPower™ MEGA uses advanced digital control, SiC switching technology, and auto-switchable transformer ratios to maintain efficient operation across changing load conditions. Internal product materials state power conversion efficiency above 95% at full load.
Cut floor space, utilities, and installation cost
One compact multi-output system can replace multiple conventional fixed-output power supplies. That means less floor space, simpler wiring and plumbing, lower cooling demand, and easier installation. Internal marketing materials describe the system as using about 75% less space than legacy technology with equivalent output power.
Handle complex thermal processes more effectively
SmartPower™ MEGA can be configured for applications such as multi-furnace melting, billet heating through the Curie transition, and multistage induction heating. Different outputs can be tuned for different process conditions, which improves flexibility and overall system utilization.
Make control and diagnostics easier
A central industrial touch panel, stored process programs, diagnostics, remote access, and PLC connectivity help operators and maintenance teams set up, monitor, and troubleshoot the system more efficiently.
Common questions about the SmartPower MEGA Systems, available from 64 kW to 1 MW per output.
What is the power range of the SmartPower MEGA?
The SmartPower MEGA scales from 64 kW to 1 MW per output using a modular architecture. Power modules can be added incrementally, so you can start at a lower capacity and expand as production demands grow — without replacing the cabinet or control system.
Can the SmartPower MEGA control multiple coils or furnaces simultaneously?
Yes. A single SmartPower MEGA cabinet can independently control up to four coils or furnaces, each with its own power output and heating profile. This makes it well suited for multi-station production lines or facilities running different heating processes from one central power source.
What is the frequency range?
The SmartPower MEGA operates from 3 kHz to 30 kHz. This low-to-medium frequency range is designed for deep-penetration heating applications such as melting, forging, hot forming, and large-part preheating. The system automatically scans and tunes to the optimal frequency for your load.
What happens if a power module fails?
The SmartPower MEGA features quick-replacement power modules designed for zero downtime. A failed module can be swapped out and replaced without shutting down the entire system, minimizing production interruptions. Built-in diagnostics help identify module issues before they cause unplanned stops.
What transistor technology does the SmartPower MEGA use?
The system uses SiC MOSFET switching technology with UltraFlex’s patented Direct Digital Step control algorithm. SiC transistors deliver higher efficiency, lower switching losses, and better thermal performance than traditional IGBT designs, resulting in reduced energy consumption and longer component life at high power levels.
What external control and integration options are available?
Standard on all SmartPower MEGA systems: 0–10V and 4–20mA external power control, remote Start/Stop, RS-485 with MODBUS protocol for PLC and SCADA integration, and a 5” color LCD touchscreen with multiple programmable heating and melting profiles. Built-in ground fault protection and diagnostic features are also included.
What applications is the SmartPower MEGA best suited for?
The SmartPower MEGA’s 64 kW to 1 MW range and 3–30 kHz frequency band make it ideal for melting (ferrous and non-ferrous metals), forging, hot forming, billet heating, and large-part preheating. The multi-output capability is particularly valuable for foundries and high-volume manufacturing operations.
Ready to Explore the Smart Power Mega Series?
Download the full datasheet for detailed specifications, or let our application engineers help you find the ideal configuration for your heating process.
