HIMMERWERK SINUS High Frequency Induction Heating Selection

HIMMERWERK SINUS Series High Frequency Induction Heating Generator: Selection, Application, and Engineering Practice

In the field of industrial heating, induction heating technology is widely used in processes such as brazing, quenching, annealing, melting, forging, etc. due to its advantages of high efficiency, precision, and repeatability. The SINUS series high-frequency induction heating generator launched by German company HIMMELWERK covers a power range of 5kW to 25kW and a frequency range of 50kHz to 2000kHz, providing a flexible and reliable solution for small and medium power induction heating applications. This article is based on the technical data of SINUS series products, providing engineers with a comprehensive technical guide from the aspects of model parameters, working principles, selection points, cooling system design, typical applications, and engineering maintenance.

Overview of SINUS Series Products

The SINUS series is a transistor based high-frequency generator designed by HIMMERWERK specifically for industrial induction heating. It adopts IGBT/MOSFET technology and features high efficiency, high reliability, and 100% duty cycle. This series covers 10 models, which can be divided into the following categories based on output power and frequency range:

Power level, model, output power, frequency range, typical applications

5kW SINUS 51 5 kW 500-1000 kHz small parts brazing, fine quenching

5kW SINUS 52 5 kW 1000-2000 kHz surface heating for small parts

5kW SINUS 55 5 kW 200-500 kHz medium depth heating

6kW SINUS 62 6kW 50-200 kHz deep penetration heating

10kW SINUS 101 10 kW 500-1000 kHz universal brazing and quenching

10kW SINUS 102 10 kW 1000-2000 kHz high-frequency surface heating

10kW SINUS 105 10 kW 200-500 kHz intermediate frequency universal

12kW SINUS 122 12 kW 50-200 kHz Thermal and Annealing

25kW SINUS 251 25 kW 500-1000 kHz high-power brazing and hardening

25 kW SINUS 252 25 kW 1000-2000 kHz high-speed surface heating

Core advantages:

High efficiency (>90%), reducing operating costs

100% duty cycle, capable of continuous operation

All parameters are programmable to ensure process repeatability

No need for deionized cooling water, reducing maintenance requirements

Ready to use, no preheating waiting

Compact external heating head that can be connected via flexible cables

Optional Profibus and Profinet interfaces for easy integration

Detailed explanation of technical parameters

2.1 Electrical Parameters

All SINUS series generators are powered by three-phase 400V ± 10% (other voltages can be customized), with a power factor of 0.95.

Model Input Capacity Input Current Recommended Fuse

SINUS 51/52/55 5.5 kVA 9 A 16 A

SINUS 62 6.5 kVA 10 A 16 A

SINUS 101/102/105 11 kVA 16 A 25 A

SINUS 122 13 kVA 19 A 32 A

SINUS 251/252 28 kVA 41 A 63 A

Engineering Tip: In actual power distribution, it is necessary to consider the voltage drop and simultaneous coefficient of the circuit. It is recommended to select fuses one level higher than the rated current (such as 16A corresponding to the actual load of 9A, leaving sufficient margin). The input terminal needs to be equipped with a fast fuse or circuit breaker and comply with local electrical regulations.

2.2 Cooling water requirements

During the induction heating process, power devices (IGBT, MOSFET) and heating coils (inductor) generate a large amount of heat, and water cooling must be used. The requirements for cooling water in the SINUS series are as follows:

Model Water Flow Input Pressure Differential Water Temperature

5-6kW level 4-5 L/min<6 bar>3.5 bar 18-25 ℃

10-12kW grade 6-9 L/min<6 bar>3.5 bar 18-25 ℃

25kW level 10-12 L/min<6 bar>3.5 bar 18-25 ℃

Key points:

No need for deionized water: ordinary industrial softened water is sufficient, greatly reducing operating costs.

Pressure difference requirement: The inlet and outlet pressure difference should be greater than 3.5 bar to ensure sufficient flow rate to remove heat.

Water temperature control: 18-25 ℃ is optimal. Excessive temperature may cause overheating and derating of power devices, while insufficient temperature may cause condensation.

Water quality suggestion: conductivity<500 μ S/cm, pH value 6.5-8.0, no suspended particles.

Cooling system configuration suggestion:

Use a closed-loop cooling system (such as a water chiller) to save water and ensure water quality.

Install flow switches and temperature sensors in the waterway, interlock with the generator, and automatically shut down when the flow is insufficient or the water temperature is too high.

Regularly clean the waterway filter (recommended to check weekly).

2.3 Mechanical dimensions and weight

The SINUS series adopts a split design: the power unit (main cabinet) and the external circuit unit (heating head).

Power level, power unit size (W × H × D), power weight, external circuit size, external circuit weight

5-12kW 380-400×280×320-420 mm 28-33 kg 120×140×240 mm 7 kg

25kW 600×1100×600 mm 110 kg 250×300×170 mm 28 kg

Engineering Tip: The 25kW model has a large size and requires sufficient installation and maintenance space to be reserved (front and rear door opening distance ≥ 800mm). The external heating head can be installed on a robotic arm or fixture and connected to a power cabinet through flexible cables, with a maximum distance of 10-15 meters (considering the influence of cable inductance).