The Melt-Manager Plus is a PC-based touch-screen control system for Inductotherm VIP series induction power supplies, scaling from 15 kW to 24 MW across VIP-I, VIP-I Plus, VIP, and VIP Multi-Output units. It automates the complete melt cycle — cold-start preheat, kWh-based energy targeting to pouring temperature, and automatic reduction to hold power — replacing manual operator control with repeatable, logged melt recipes.

How does kWh-based melt control work?

Instead of relying on operator judgment or timer-based heating, the Melt-Manager Plus calculates the energy required per ton of charge material and delivers it precisely. When the target kWh is reached, the system automatically switches to hold power or shuts off at pouring temperature. This eliminates over-heating, reduces energy waste, and produces consistent melt quality from batch to batch — independent of operator experience level.

What sintering and lining management features are included?

Four operator-entered sintering steps are supported, each with configurable heating rate, target temperature, hold time, and maximum temperature deviation. The system also calculates furnace inductance to estimate refractory lining condition over time, providing an early warning before lining failure. Cold-start scheduling with preheat ramps protects new or cold linings from thermal shock.

How does the system integrate with plant-level networks?

Ethernet TCP/IP exports daily data logs — metering, alarms, events, and inductance readings — in spreadsheet-compatible formats. The Ethernet Industrial Protocol interface connects to PLCs and host supervisory systems for remote monitoring and recipe management. An optional SMS text messaging module sends selectable melt status, alarm, and event notifications to mobile phones.