ENG

THYRISTOR & IGBT TECHNOLOGIES

WWW.5MTR.COM

INDUCTIONMELTING / HEATING / HOLDING

SYSTEMS

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5M serves in thousands of foundries and steel plants in 4 continent and 35 countries5M Elektromekanik, having so long and deep rooted history about induction melting system, is an international establishment founded in 2002. 5M, whose head office and the place of production placed in Istanbul, serves with broad sales and service network (see map) in a wide area all over the world.Products and services for induction melting systems with related sector and fieldInduction Melting Systems for Steel Plants up to 400.000 ton/yearØ Foundry Plants from 1kg up to 30ton/hour and more.Ø Special Melting systems for Steel, Cast-Iron, Ductile Iron, Grey Iron, Copper, Brass, Aluminum and other ferrous and non-ferrous alloys.Ø Turnkey Steel PlantsØ Hot Rolling MillØ Continuous Casting MachineØ Mini melting systems for laboratories and precious metalsØ Induction heating systemsØ Moveable crucible melting systems for non-ferrous metalsØ Double frequency or variable frequencies Induction Melting SystemsOur Successful experiences and capacity on induction melting systems to meet your needs makes us valuable supplier and service center for you. We carry out your projects with mutually cooperation and trust as per your demand. AZERBAIJAN

IRAQ KAZAKHSTAN K.S.A MACEDONIA MEXICO NORWAY POLAND ROMANIA RUSSIA SPAIN SWEDEN SUDAN JORDAN DENMARK TURKMENISTAN GAMBIA NAKHCHIVAN MALI

1800kW Melt&Hold System at the time of casting - Turkey

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5M Agents and Services 5M References

5M World References TURKIYE BRAZIL BULGARIA COLOMBIA EGYPT IRAN GREECE LIBYA MALAYSIA SOUTH KOREA SYRIA THAILAND UKRAINE INDONESIA SERBIA

5M IGBT 225kW 2x150KG

İ N D E X Ø About 5M Ø Pictures of 5M Systems from South Korea & Egypt Ø 5M technological advantages and superiorities Ø About 5M SCR technologies Ø Advantage of 5M IGBT technologies Ø Box type melting furnaces / 10kg-3000kg Ø Steel construction melting furnace / 500kg-30TON Ø 5M Heating Systems Ø 5M Mini Melting Systems Ø Operating Systems / SCADA – PLC Ø SCR Melt&Hold systems Ø SCR double frequency melting systems Ø Modular design IGBT Technologies Ø Steel plants Ø Accessories Ø Power and capacity table

Sayfa0203

04-0506070809101011121213141516

ABOUTABOUT

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10000kg induction furnace at the time of operation – South Korea

2x2000kW ve 3x3000KG steel melting system at the time of operation - Egypt

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5M MELTINGPROVIDE ADVANTAGE VIA

SOLUTIONSSUPERIOR TECHNOLOGY

Ø Network protections and high–speed input fuses for maximum system protection • High-speed protective fuses on the transformer output for system protection • High-speed semi-conductor protection class fuses on the converter input • Thermic magnetic switch against current overload • Standard Input Over Current Protection Circuits • Standard Input Over Voltage Protection Circuits

Ø Easier to use through next generation operator panels and Reporting System Specially designed for easier to use of operator, distinctly visible under foundry conditions, bright, digital and analog displays, operator panel and keypad. All necessary displays on panel such as temperature, pressure, kilowatt meter, earth leakage, volt meter, frequency… • Getting Status reports easily by record keeping facility on internal memory integrated PLC and SCADA systems. • If required daily, weekly or monthly period reports can be printed out. • SMS status and warning messages transmission.

Ø Capacitor Bank and Transfer SwitchLong life power capacitors through professional capacitor protection measures; • Long life with installation of earthen full insulation • Analog temperature sensor on each capacitor • Pressure sensor on each capacitor • Total capacitor pressure data • Total capacitor temperature data • Easy assembly and maintenance

Ø A class, water cooled energy cables • Made from high purity copper conductor, stranded, multicore energy cable • Free water transition, internal cooling water channel • Mounting and maintenance facility with easy demountable connections • High insulation class ≥5000VAC • A class carbon free insulating hose • Steady-state operation through high pressure cooling water • Excellent sealing under high pressure with double or triple stainless steel clamps connecters on both terminal points

Ø Primary Or Secondary Insulation Solutions Ø Easy service and maintenanceHIGH  

VOLTAGE  

FURNACE  INSULATED  INPUT    

POWER  TRANSFORMER  

C  Inverter   380V  AC  

HIGH  FREQUENCY  INSULATION  

TRANSFORMER  

Inverter  

FURNACE  

C  

SECONDARY    INSULATION  DIAGRAM  

PRIMARY INSULATION DIAGRAM

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5M MELTINGPROVIDE ADVANTAGE VIA

SOLUTIONSSUPERIOR TECHNOLOGY

Ø Single Control Board managing Overall SystemSingle Digital Control Board, improved by current and new technologies, has a design providing high safety and efficiency conditions .Ø All adjustments are loaded beforehand and necessary adjustments can be done through computer if required. Ø No need for special setup in future or during commissioning

Ø Early Warning Detecting System • Controls the level of Earth Leakage • Gives idea about lining getting thinner • Adjustable sensitivities • System can stop automatically by PLC when liquid metal approaches the coil. • Approach of metal to coil is prevented with thickness of lining and coil surface continuously controlled by electromagnetic control system.

Ø High efficiency coil conductor

Ø International standard spare parts; • Electronic components can be supplied by readily available global producers • Manufacturers, brands and product codes of all power electronic components are international standard. • 5M products do not include hidden brands and international codes data of power electronic components such as power thyristors, capacitors, resistors etc.

Ø Closed Circuit Water Cooling System

• Closed circuit deionized pure water cools converter, capacitors, thyristors, busbars, reactors etc.

• There is a pressure and sensitive temperature control on all lines.

• PLC warns operator in case of a problem in the cooling system and provides necessary treatment facility

• Demineralized water conductivity control constantly and warning operator.

Ø Full safety for all systems; Operation temperature of all components on system, especially thyristor and capacitors is not more than max. 60ºC. Thus, defects caused by high temperature are prevented and total system quality is increased.

Water cooling tower

Furnace 1

Furnace 2

ThermostatsPressuresensor

Plated heatexchanger

Water pump

Transformer

Convertor

Capacitor unit&

transfer switch

Water pump

Block diagram of cooling system

Water tank

5M always uses rectangular, high purity copper coil conductor

Other Manufacturers

Earth Leakage Sensitivity

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Excellent Driver Technology

High Safetyand Efficiency

withEnhanced

ParallelResonance Technology

5M PMT+ 5700kW Melt&Hold Power Converter Single power panel for Melt&Melt or dual power output ; Melt&Hold/Process

5M PMI 225kW 350kg+750kg special movable furnace 50kW 25KG IGBT controlled manuel tilting melting furnace at the time of casting– Gebze

M e l t i n g s o l u t i o n s f o r s p e c i a l a l l o y s

B r a s s m e l t i n g

EXCELLENT DRIVER TECHNOLOGYEXCELLENT DRIVER TECHNOLOGYPower Prestige SCR: PPT Series

Power Ranges: 50kW – 10.000kW

Ø High efficiency at full power

Ø High cos Ø ≥ %98

Ø Bath temperature control with optic sensor

Ø Industrial energy analysis process

Ø Provides single or double furnaces to work with

double frequency

Ø Remote troubleshooting and program

update with modem

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5M PMI-1 IGBT 225kW 500kg copper melting system, Spain 5M PMT 600kW 1000kg aluminum melting system, Izmir – Turkey

C o p p e rM e l t i n g

A l u m i n u m M e l t i n g

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Excellent Driver Technology

ADVANTAGES OF MODULAR DESIGN IGBT TECHNOLOGIESØ Compensation-free in every operating condition, so there is no installation and maintenance costs of compensation. Ø Upgradable converter power with parallel module technology Ø Simple replaceable power modules in case of trouble and service requirement. Ø 5M parallel module IGBT technology provides opportunity to continue at low power with other modules as faulty module easily unmounts in case of trouble in one of modules.

Ø Excellent coil protection systemØ Operation in local languagesØ Short message (SMS) warning systemØ Probeless automatic sinteringØ Automatic crucible preheatingØ Energy monitoring and consumption reporting via remote connectionBlock diagram of 5M PMI Series IGBT

controlled Expendable modular power supply

5M PMI 2+1 1600kW Power Sharing for Holding/Process

EXCELLENT DRIVER TECHNOLOGYEXCELLENT DRIVER TECHNOLOGYPower Prestige IGBT: PMI SeriesPower Ranges: 5kW – 5.000kW

5M USER

INTERFACE

MODUL WITH

PLC

5M

MULTI ODUL

CONTR

5M USER INTERFACE WITH PLC

5M IGBT MULTI

MODUL CONTROL SYSTEM

IGBT POWER MODULE - 1

IGBT POWER MODULE - 2

EXPANSION SLOT POWER INCREASE

CAPACITOR BANK

MAIN

1000kW

1000kW

SMOOTHING CHOKE-1

SMOOTHING CHOKE-2

4000KG

4000KG

Block diagram of 5M PMI Series 2000kWIGBT Controlled Power Supply with Expansion Slot

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CORELESS INDUCTION MELTING FURNACES

• High-alloy antimagnetic aluminum casting side plates condensing magnetic area inside of furnace• High heat gain by hydraulic controlled lid covering furnace intake full well and high durability fixed refractory put in lid• Fixed Gas Ring vacuuming smoke through furnace intake• Easy reach and treatment with removable rear/front cover• Supported by steel construction stands• Installation and commissioning in a short time• Space saving with compact design• Hydraulic safety with mechanical lock • Hydraulic controlled furnace lid • Fixed exhaust ring for environmental conditions • Easy to service and maintenance

1000kg Box Construction Furnace at the time of casting

Box Type Melting FurnaceCapacity ranges from 10KG – 3.000KG

5M Box construction furnace,Hydraulic furnace coverFixed exhaust ring

Crucible melting furnaces for non-ferrous melting applications

5M BOX construction furnace manufacturing plant

15T furnace manufacturing

CORELESS INDUCTION MELTING FURNACESCORELESS INDUCTION MELTING FURNACES

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CORELESS INDUCTION MELTING FURNACES

• High efficiency special design

• Long life quality equipment and labor

• Excellent insulation and safety by special materials

• Suitable design for safe and fast charging-discharging

• Special 5M design magnetic yokes preventing induction

current diverging

• Maximum efficiency under hard working conditions

• Easy to service and maintenance with demountable top

cassette

• Minimum sound level under heavy working environment

• Long life coil via water cooled magnetic yokes winding coil

• High durability lining with extra water cooled turns

completing bottom and top turns.

• Anti heat loss design for molten metal

• Hydraulic system secured by mechanical lock

Special furnace design1500kW 2x3000kg melting furnace at the time of casting – Norway

5M design coreless induction melting furnace with all accessories safety back and side barriers back tilting,capture hood and easy lining removal system

Hydraulic furnace lid

Gas vacuuming system

Demountable top cassette

design

High insulated shielding system on energy inputs

First class coil insulation

Rectangular coil conductor

Magnetic Yokes

Discharge outlet

Automatic Lining Removal System

Reinforced cooling turns in bottom and

top concrete for homogeny cooling of furnace lining

Steel Construction FurnacesCapacity ranges from 500KG – 30.000KGCORELESS INDUCTION MELTING FURNACESCORELESS INDUCTION MELTING FURNACES

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3000kW 6000kg + 4500kW 6000kg melting systems at the time of operation – South Korea

ØTunnel Heating SystemsØPipe and joint heatingØSpecial heating systems for forging plantsØVariable and double frequency heating solutionsØSpecial heating projects for processØSpecial heating solutions for copper, bronze, iron, steel,

stainless steel and special alloysØ1,2,3 or 4 headed heating solutions with variable frequencies

and at the same time from single power unit

5M IGBT Controlled Heating System

From 1 kg to 30 kg IGBT controled melting systems suitable working laboratory conditions together with valuable and specific metal casting prpcesses.

ØDirectly input voltage ‘’380V or 440V‘’ØSmall place with Compact design ØTilting system with reductorØCooling with city water without any specific water installation.

5M IGBT Controlled Mini Melting Systems5M PMI Series

laboratory type systems1kg - 30kg mini

melting sets

15kW – 10kg IGBT laboratory systems

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PRINTER

MONITORCOMPUTER

FYBERR OPTIC DATALINK

5M POWER UNIT

MAIN CONTROL SYSTEM

REMOTE CONTROLSYSTEM 2

REMOTE CONTROLSYSTEM 2

TEMP SAMPLER 2

TEMP SAMPLER 1

TEMP PROBE 2

TEMP PROBE 1

LIMIT SWITCH

LOADCELL

Ø Graphic interface programØ Furnace power Ø Metal weight Ø Heat tracking systemØ Calculation of energy Ø Easy energy control mode, Ø Instant, daily, weekly and monthly energy reportsØ Heat control script; Ø Calculation of consumptive power and metal weight, Ø Instantaneous heat profile, casting heat target, calculation of time and casting heat according to molten metalØ Presentation of all warning and fault messages, Ø Explanation of solutions or alternative methods, Ø Saving of event records and reporting events.

Ø Modern technologies

Ø Instant status information of system.

Ø Probeless auto sintering program for fast and slow sintering process

Ø Automatic error logging memory

Ø Display error messages audible

Ø Remote monitoring by internal modem troubleshooting

Ø Easy way to operating by HMI touch screen

Ø Operation in local languages and different character sets. Cyrillic, Chinese,

Arabic, Korean etc

Ø SMS through on GSM ; Short message warning system can send SMS to

person in charge, Easy way to control and operation

Ø Crucible heating program

Operation Desk

SCADA CONTROL SYSTEM

PLC CONTROL SYSTEM

Control Cabins

PLC Information Screens

Block diagram of Scada control system

MODERN OPERATION SYSTEMSEASY USE, CONTROL AND REMOTE

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THE BEST MELTSteel, Stainless Steel, Cast-Iron, Ductile Iron, Grey Iron,

ING SOLUTIONSCopper, Brass, Aluminum Ferrous and Non-Ferrous Alloys.

Single Melting Systems up to 10.000kW

Melt&Hold Melting Systems up to 15.000kW

Double Frequency Melting Technology for Special Melting Process

Ø Modern DesignØ Easy to useØ Low costØ Standard operator panelØ New generation power electronic components

With its compact design takes a small place. With organized and systematic structure not only construction installation but also operation and maintenance costs are very economical.

Ø Improved for foundries whose target is to have high capacity casting. It takes less place and more economic than other systems. The difference from other standard melting systems is to have capability to choose required power and holding capacity.Ø While a furnace is working with full power, the other is either working with full power or just holdingØ Its usage is very simple. With only a single touch one of the furnaces enters the melting mode and the other enters waiting or holding hot mode.Ø There is a twin power unit technology in single converter panel having independent operation ability.Ø When melting converter breaks down, holding converter supports.Ø During a power cut holding converter holds molten metal in furnace hot with a suitable generator.Ø In case of a problem at one of the lines, with the opportunity of joining by two different energy lines, the other system continues its operation.Ø Foundation & civil work costs and operation & maintenance charges are so economic with its methodical and organized structure

Capability to work with one furnace at 2 different frequencies , and by feeding just from single power converter capability to work with 2 or more melting furnace at different frequencies and power. Classified different from other melting Systems and designed for user’s requirements. Improved specially by 5M RD Engineers for preparation of different characteristic alloys.

Ø Sample Configuration 1 : during melting process of existing one melting furnace, operator can choose one from 2 different melting frequencies within few seconds in any time and apply to material inside furnace. Frequency can be changed over and over again.

Ø Sample Configuration 2 : Designed for operation at different frequencies or power for 2 or 3 furnace melting Furnaces. For instance while furnace-1 is working at 1000Hz , Furnace-2 can continue to work at 3000Hz.

3150

2110

950

Minimum platform size

Power Prestige SCR: PPT SeriesPower Ranges: 50kW – 10.000kW

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THE BEST MELTSteel, Stainless Steel, Cast-Iron, Ductile Iron, Grey Iron,

ING SOLUTIONSCopper, Brass, Aluminum Ferrous and Non-Ferrous Alloys.

IGBT Single Melting Systems up to 5.000kW

IGBT Controlled Power Sharing Melting Systems up to 5.000kW

IGBT Melt&Hold Melting Systems up to 6.000kW

Ø Compensation-free in every operating condition, so there is no installation and maintenance costs of compensation. Ø Upgradable converter power with parallel module technology Ø Simple replaceable power modules in case of trouble and service requirement. Ø 5M parallel module IGBT technology provides opportunity to continue at low power with other modules as faulty module easily unmounts in case of trouble in one of modules. Ø Operation with %30 higher capacity by comparison with normal systemsØ New generation electronic drivers with DSP processors Ø New generation components of power electronicØ Quality below legal limit, proper and safe energy consumption

Ø High Power Factor (Cos Ø ≥ 0,98)Ø Keeping hot for holding or compensationØ Preparation alloy Ø Probeless automatic sintering Ø Scrap pre heatingØ Furnace heatingØ Alloyed casting at high temperatureØ No compensation system

Ø Compensation-free in every operating condition, so there is no installation and maintenance costs of compensation. Ø Upgradable converter power with parallel module technology Ø Simple replaceable power modules in case of trouble and service requirement. Ø 5M parallel module IGBT technology provides opportunity to continue at low power with other modules as faulty module easily unmounts in case of trouble in one of modules.

It provides melting on both furnaces at the same time or while one furnace works at full power, the other furnace works with process power to proceed on molten metal inside, by sharing power between 0% and 100% ranges on high efficiency with independent power outlets working with single operating system

Ø Economic energy feeding at the same time from single or dual energy line with dual working opportunity.Ø High safety IGBT power modules by independent full controlled input redressersØ %100 More production possibility with just increase in transformer power via independent redressers integrated to modules suitable increase in capacity for future projects. Ø Easy use by user friendly operating system and touch screen PLC interfaceØ While one furnace works at full power, other one works at holding power at the same time to prevent holding losses.

Ø Improved for foundries whose target is to have high capacity casting. It takes less place and more economic than other systems. The difference from other standard melting systems is to have capability to choose required power and holding capacity.Ø While a furnace is working with full power, the other is either working with full power or just holdingØ Its usage is very simple. With only a single touch one of the furnaces enters the melting mode and the other enters waiting or holding hot mode. Ø There is a twin power unit technology in single converter panel independent operation ability. Ø During a power cut holding converter holds molten metal in furnace hot with a suitable generator. In case of a problem at one of the lines, thanks to the opportunity of joining by two different energy lines, the other system continues its operation.

ADVANTAGES OF MODULAR DESIGN IGBT TECHNOLOGIESPower Prestige IGBT: PMI SeriesPower Ranges: 5kW – 5.000kW

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40MW – 4x25TON 400.000 ton/year Mini Steel Plants

Ø Turn-Key Steel Plant Solutions Ø Continuous induction melting systems Ø Continuous casting machine (CCM) Ø Hot rolling mills Ø Steel melting and applications Ø Laddle refining furnace (LRF) Ø Ingot melting solutions

5M Melting furnace during casting to ingot moulds

5MW 2x8T Steel melting furnace during operation-Iraq

Runing foundry in operation with sand moulding line

Billet production with horizontal permanent molds

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STEEL PLANTSSTEEL PLANTS

Continuous casting machine

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Backward and forward movable exhausted furnace cover

5M Induction Furnaces present useful design for environmental protection by keeping venting specks at minimum level with active dust and smoke collecting system.

Vibratory, pneumatic, automatic refractory forging device

GasSuction

GasSuction

GasSuction

Dust anddirty gas

Induction furnace Cyclone Filter Dustcollecting

Absorptionsystem

Clean Gas

Bottom ramming

Furnace weighing systemAutomatic Lining Removal System

Fixed exhaust gas suction system and hydraulic furnace cover

Vibratory furnace charging car Hydraulic controlled furnace cover

Furnace Back TiltingFurnace Back Barriers

Enviromentally friendly dust and smoke collecting filter system

Side ramming

ACCESSORIESACCESSORIES

For other materials, multiply melt rate for steel by the following values: Aluminum: 1.0 – Copper: 1,6 – Silver: 2,85 – Gold: 5,0

CONVERTER FURNACE STEEL IRON BRASSPOWER

(kW)CAPACITY

(kg)@1650°C

(kg/h)@1480°C

(kg/h)@1170°C

(kg/h)10

00-3

000H

z

75 100 100 110 190100 150 132 144 251125 150 185 205 352150 200 225 245 428175 200 270 300 513200 250 315 345 599225 300 375 405 713250 350 430 475 817

500-

3000

Hz

300 500 530 590 1.007325 350 570 635 1.083350 500 625 680 1.188400 750 725 815 1.378450 750 815 900 1.549500 1.000 900 1.000 1.710600 1.000 1.090 1.200 2.071750 1.500 1.430 1.575 2.717

200-

600H

z

800 1.500 1.522 1.659 2.8921.000 2.000 1.900 2.100 3.6101.250 2.000 2.380 2.625 4.5221.500 3.000 2.860 3.150 5.4341.750 3.000 3.340 3.675 6.3462.000 4.000 3.820 4.200 7.2582.500 4.000 4.770 5.250 9.0633.000 5.000 5.725 6.300 10.878

100-

300H

z

3.500 6.000 6.680 7.350 12.6924.000 6.000 7.635 8.400 14.5075.000 8.000 9.545 10.500 18.1366.000 10.000 11.460 12.600 21.7747.000 12.000 13.360 14.700 25.3848.000 16.000 15.270 16.800 29.013

10.000 20.000 19.000 21.000 ----10.000 25.000 19.000 21.000 ----

Dudullu OSB. DES San.Sit.102 Sk. A.4 Blok N.42 34776Ümraniye İstanbul TÜRKİYE

T. +90 216 527 83 54F. +90 216 527 85 24

info@5mtr.com www.5mtr.com

www.kosgeb.gov.tr05.09.2014

Print: Tematik Medya

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