SmartPower™
MEGA
Flexible. Scalable. Future-Proof.
The multi-output induction melting solution built for modern foundries and melt shops.
One cabinet. Up to 4 independent outputs. 50 kW to 1 MW.
Core Platform
SmartPower™ Technology
Four foundational technologies combine to deliver industry-leading performance, reliability, and efficiency for the most demanding induction melting and heating applications.
- 01
Modular Architecture
Multiple RF power modules independently controlled as separate outputs or synchronized as one system — enabling simultaneous control of multiple melting furnaces from a single power supply.
- 02
Advanced Power Conversion
Patented topology with Direct Digital Step control and cutting-edge algorithms for highly efficient power conversion across all load conditions and frequencies.
- 03
Next-Gen SiC Semiconductors
Latest Silicon Carbide (SiC) transistor technology for superior energy efficiency — delivering significant energy savings in high duty-cycle melting and holding operations.
- 04
Industrial Touchscreen Interface
15” industrial-grade touchscreen operable with heavy gloves, lockable controls, multi-level access — purpose-built for foundry floor environments.
Configurability
One Cabinet. Up to Four Independent Outputs.
From small-batch precious metal melting at high frequency to large iron and steel furnaces at low frequency — all from a single platform.
Output Power Range
Output
Output
Output
Output
Output 1 — 256 kW | 3–30 kHz (steel / iron melting)
Output 2 — 150 kW | 40–200 kHz (aluminum / non-ferrous)
Purchase based on current power needs. Add modules and outputs to the same cabinet as production grows — no new system required.
Built to Last
Strength & Dependability
Proven industrial design engineered for the harshest foundry environments — heat, dust, metal splash, and continuous 24/7 duty operation.
- 01
Industrial-Grade Components
High-quality power electronics rated for continuous duty melting applications, proven in demanding environments worldwide.
- 02
Sealed Enclosures
Rugged IP54/NEMA 3S sealed cabinets protect electronics from dirt, dust, and liquid splash common to foundry floors.
- 03
Melt Shop Controls
Stainless steel vandal-proof push-buttons and knobs operable with heavy gloves, with lockable covers to withstand heat, dust, and metal splash.
- 04
Ruggedized Foundry Option
Optional IP65/NEMA 4X stainless-steel enclosure for washdown installations and outdoor or harsh foundry environments near furnaces.
System Architecture
Flexible System Architecture
Unmatched frequency coverage and intelligent load matching ensure peak performance across every phase of the melting cycle.
Wide Output Frequency Range
Spanning 2.5 kHz to 250 kHz — from large iron and steel coreless furnaces at low frequency to non-ferrous and precious metal melting at high frequency.
Flexible Tuning & Remote Heat
- ✓
Auto-Switchable Transformer Ratios
Ultra-flexible load impedance matching — critical during the melting cycle as load impedance changes with temperature and metal phase.
- ✓
Remote Heat Stations
Optional remote heat stations up to 30 ft (10m) from the power supply cabinet. Ideal for complex furnace layouts.
- ✓
Field Upgradeable
Reconfigurable in the field. Rapid switching between processes with minor changes to power module configuration — no new system needed.
Energy Performance
Industry-Leading Energy Efficiency
SiC-based power conversion delivers measurable cost savings for high duty-cycle foundry operations — reducing energy draw, improving power quality, and eliminating costly harmonic filter installations.
| Parameter | SmartPower MEGA (SiC) | Other IGBT Technologies | SCR Technologies |
|---|---|---|---|
| Power Conversion Efficiency | ✓ Excellent >95% | Acceptable 80–90% | Acceptable 75–80% |
| Power Factor | ✓ Excellent >0.99 | Acceptable >0.9 | ✗ Poor <0.9 |
| Response Time | ✓ Very Fast | Fast | ✗ Slow |
| Frequency Bandwidth | ✓ Very Wide 2–250 kHz | Wide 1–100 kHz | ✗ Narrow 0.1–1.0 kHz |
Modern User Controls
Industrial-grade controls designed for the realities of foundry floor operation — robust, intuitive, and fully connected to your plant network.
15” Industrial Touch Panel
Industrial-grade touch panel for process tuning with multi-level access control (Operator / Process / Service levels).
Central Multi-Output Control
One panel controls 1 to 4 independent outputs. Manual backup via industrial-grade pushbuttons and knobs operable with heavy foundry gloves.
Melting Cycle Management
Store parameters per metal type and furnace — power level, current, heat and hold profiles, soak and ramp times. Real-time energy-per-heat tracking.
PLC & Network Ready
Connects to all standard PLCs or PCs via RS-485 or Ethernet for remote access, data collection, and diagnostics. Industry 4.0 ready.
Easy Maintenance & Zero Downtime
In a 24/7 foundry operation, unplanned downtime means lost production and potentially solidified metal in furnaces. SmartPower MEGA is engineered to keep running.
- 01
Simplified Modular Design
Integrated modular design eliminates wire harnesses. Minimal spare parts required for continuous operation.
- 02
Independent Output Operation
If one output fails, the remaining outputs continue uninterrupted. Other furnaces keep running while service is performed.
- 03
Redundant RF Module Option
An optional extra RF power module automatically compensates for a failed module, maintaining full system capacity until replaced.
- 04
Built-in Diagnostics
Detailed fault messages and troubleshooting guidance on the touch panel. Remote diagnostic access enables proactive maintenance.
Replace Two with One.
The SmartPower MEGA 512 kW replaces two separate 250 kW legacy power systems — eliminating two electrical drops, two cooling circuits, and two-thirds of the floor space. Shown: two ITC 250 kW systems vs. one SmartPower MEGA 512 kW.
Replace three legacy 250 kW SCR-based power supplies with a single SmartPower MEGA 750 kW unit, reclaiming two-thirds of melt shop floor space.
One electrical panel and one cooling circuit instead of multiple drops for separate systems. Simplified installation and commissioning.
Higher conversion efficiency means less heat rejected — smaller chiller, lower water treatment costs in high duty-cycle melting operations.
Dramatically reduced size and weight means significantly lower freight costs compared to multiple legacy power systems of equivalent capacity.
Application
Induction Melting
| Independent Furnace Control | Melting Multiple Metals | Scalable Architecture |
|---|---|---|
| Each furnace independently controlled with its own power and frequency settings, or outputs switched and operated sequentially — including temperature hold between pours. | Configure per output: ferrous (iron, carbon steel, tool steel), non-ferrous (aluminum, copper, brass), and precious metals (gold, silver, platinum). | Up to 4 independently controlled melting furnaces of different capacities. Add modules to an existing cabinet as production grows — no new system required. |
Application
Billet Heating, Forging & Melting
When magnetic materials like carbon steel or iron are heated beyond their Curie Temperature (~770°C), they lose magnetic properties and load characteristics change dramatically — causing conventional systems to operate inefficiently.
Magnetic Phase
High magnetic permeability. Load optimized for low-frequency, high-efficiency operation in the magnetic state.
→
Transition
Non-Magnetic Phase
Magnetic properties lost. Load characteristics shift — requiring dynamic output matching to maintain peak efficiency.
For Melting Furnaces & Billet Heating
Mega includes an automatic output transformer ratio switch — a built-in “gear shift” that dynamically adjusts power output throughout the heating cycle. Especially valuable for steel and iron melting where the load transitions dramatically through the Curie temperature.
For Inline Bar & Billet Heating
Two optimized outputs — one for pre-Curie, one for post-Curie operation. Both the magnetic and non-magnetic phases are powered at peak efficiency, lowering energy cost per heat cycle and maximizing throughput.
Application
Induction Heating
SmartPower MEGA delivers unmatched flexibility for growing induction heating operations.
Unmatched Flexibility
Field-upgradable and reconfigurable. Rapid switching from one process to another with minor changes to power module configuration — no replacement system needed.
Scalable to Your Growth
Purchase based on current requirements. When production demands increase, add modules to the existing cabinet — no need to discard your existing system.
Maximize Space. Minimize Cost.
Two separate 250 kW systems consolidated into one 500 kW SmartPower™ dual-output MEGA unit — reducing floor space, energy, chiller size, and installation cost.
Redundancy with Purpose
Extra modules as spares reduce downtime, simplify maintenance, and future-proof your investment against production demand increases.
Talk to an ITC Melting Specialist
Induction Technology Corporation has been designing and manufacturing induction melting
and heating systems for customers worldwide. Contact our applications team to discuss your
specific requirements — furnace capacity, metals, duty cycle, and site constraints.