HRT-5K2 Induction Heating Device Manual

Navio Co., Ltd.

Product Name: Induction Heating Device
Model: HRT-5K2Nagano, Japan
TEL +81-267-63-0040
FAX +81-267-63-3418

Date: July 19, 2024

目次
１．Overview

１Ｐ

２．Configuration

１Ｐ

３．Specifications

２Ｐ

４．Operating Instructions

３Ｐ

５．Control Methods

４Ｐ

６．Operation Flow

４Ｐ

７．Safety Precautions

５Ｐ

８．Maintenance

５Ｐ

９．TroubleShooting

５Ｐ

１０．Installation Checkpoints

６Ｐ

１１．Internal Components List

７Ｐ

Appendix diagram
HRT-5K2 HRT-5K2-G01
Meter HRT-5K2-APM-G01
Wiring diagram HRT-5K2-W01!

Safety Precautions・High Voltage Charging Section:
Do not touch the terminals of the connected transformer with bare hands as
it may cause electric shock.

・Output Connection Precautions:
When connecting the device's output terminals to the transformer, ensure that wires ofdifferent colors are not connected to the same terminal to prevent short-circuiting,which could lead to device failure.

１．Overview
The HRT-5K2 induction heating device is designed to control non-contact
heating by passing high-frequency current through heating coils.
The heating operation is controlled externally, allowing for temperature
regulation via a temperature controller or on-off control by a sequencer.
２．Configuration
Induction Heating Device Power Block Diagram

Cooling fan3phaseResonance
Capacitor

30A

RectifierPower input terminal

AC200V

CurrentSensor
Noise
Filter

SmoothFilter

IGBT
ModuleResonance
Capacitor

Current Sensor

Control board
IGBT control

High Frequency out
Connecting to Transformer

signal i/o terminal

１

３．Specifications
・Power Source Voltage: 3-phase AC 200V ± 20V, 50/60Hz, max 5kW・Absolute Maximum Input Rating: 5kW・Internal Resonance Capacitor Capacity: 2.296μF ± 5% (can be reduced to 0.984μF)
・Matching coil :３０～５０μH（Q≦５）、５０～１１０μH（Q≦１０）

at 10kHz・Output Frequency: 10kHz to 20kHz
・Output Current: Rated 100A rms
・Protect Functions ・Internal Temperature Abnormality: Stops operation at 75°C
・Output Overcurrent Abnormality: Stops operation at 170A peak・Input Protection Leakage Breaker: 30A, Leakage current 30mA・Display Functions ・High-Frequency Output Lamp (Green)・Internal Temperature Abnormality Lamp (Red)・Output Overcurrent Abnormality Lamp (Red)・Heating Output Meter (Separate, Full Scale 7.5kW)
・I/O

・Heating Operation Stop/Start Input(1bit)
・System Error Output (1bit,photocoupler open collector)
Internal Temp Abnormality
and Output Overcurrent Abnormality Output
・External Control Signal Connectionfor Heating Power Adjustment (4-20mA Control Current Input)
・Power Meter Output
Connecting Meter Accessories

・Operating Tempreture

０℃～４０℃(Derating is required at 30 to 40°C.)

２

４．Operating Instructions
１）Power Supply Description
The input power supply is AC 3-phase 200V 50/60Hz.
Please ensure that all terminal connections are securely made before
turning on the leakage breaker during equipment installation.
２）Signal I/O Terminals Instructions
HRT-5K2 Internal
Signal I/O Terminals

Photocoupler

1

Operating Command＋0V2COMError out

3Error （Photcoupler Collector）

To Control

4４-２０ｍＡ＋

5４-２０ｍＡ－ or

6kw meter＋

7kW meter －VCC

249ΩMeter Drive out

The operating command is activatedby short-circuiting terminals 1-2.

To PLCWhen the photocoupler is ON, an error occurs.

or １-５Ｖ＋

１-５Ｖ－

4-20mA

input +

4-20mA

input -TMRD-21 1mA FS7.5kW+-FS 1mA

8 N.C.

Inside the HRT-5K2: The 4-20mA control current is converted to a 1-5V voltage signal by theinternal 249Ω resistor, controlling the input power between 20% and 100%.
The HRT-5K2 stops operation for inputs below 1V (4mA).

３）Front Display Lamps①High-Frequency Output (Green) 高周波出力中 （緑）Lights up when high-frequency output is generated during heating operation.

②Internal Temperature Abnormality (Red) 内部温度異常 （赤）Lights up and stops operation when
the internal temperature reaches 75°C for protection.

③Output Overcurrent Abnormality (Red) 出力過電流異常 （赤）Lights up and stops operation when overcurrent occurs.
To resume, the power must be turned off and restarted.

４）Heating Output Meter
Indicates the current heating output through an externallyconnected power meter.
３５．Control Methods① Temperature Controller Control
To control the temperature of the heated object using a temperature controller, connect the 4-20mA
output of the temperature controller to the temperature input. Once the operating command isinput, the temperature will be automatically maintained at a constant level.
② Timer Control by Sequencer(Programmable Logic Controller)
If you do not use a temperature controller, you can manage heating by controlling the duration ofthe operation command issued by an external timer. In this case, input either 4-20mA current or 1-5V
voltage to the temperature input to maintain a constant heating output during the timer operationof the external sequencer.
Important: Do not input a current or voltage exceeding 24mA or 6V to the temperature input as it
may cause device malfunction.

６．Operation Flow
Basic operation flow:
Power On

(example of control by temperature controller)

Operation CommandStart High-Frequency Output

Temperature RiseOutput decreases as it approaches the set temperature

Intermittent Operation upon reaching the set temperature

４７．Safety Precautions
・High Voltage Charging Section:
Do not touch the terminals of the connected transformer with bare hands as
it may cause electric shock.

・Output Connection Precautions:
When connecting the device's output terminals to the transformer, ensure that wires ofdifferent colors are not connected to the same terminal to prevent short-circuiting,which could lead to device failure.
８．Maintenance・The cooling FAN
The cooling fan located at the bottom of the device is a consumable part.
If the device is operated continuously for 24 hours a day, 365 days a year,
it is recommended to replace the fan every two years.

９．Trouble Shooting・Heating Operation Not Starting:
Ensure the voltage between the temperature input terminals is 1-5V.
Even if the operating command is input, heating output will not be generated
if the voltage between the temperature input terminals is below 1V.
・Output Overcurrent Abnormality:
Check if the heating load is properly set in the coil.
Verify that the device output is not short-circuited.
・Internal Temperature Abnormality:
If the internal temperature of the device reaches 75°C, the red lamp willlight up and the device will stop operation to protect itself.
Ensure the ventilation is not blocked and the cooling fan is functioning properly.
・Leakage Breaker Trips:
Inspect for any leakage from the device output or consider the possibility ofdevice failure. If the breaker continues to trip after correcting the suspectedleakage point, contact the manufacturer for assistance.
５１０．Installation Checkpoints
The HRT-5K2 device, upon delivery, is not connected to the oscillator,transformer, or heating coil. Therefore, assembly is required after unpacking.
Please confirm the following management data during assembly:①Tightening Torque During Assembly:
Ensure the tightening torque for the three-phase power supply terminal
is between 2.2 and 2.8 N ·m.

②Current Waveform Confirmation Between Oscillator and Transformer:
Use a current transformer (CT) and an oscilloscope to confirm the high-frequency
current waveform flowing between the oscillator and transformer.
The CT should be connected with a resistor at both ends. When alternating current
flows through the wire clamped by the CT, a current proportional to the turns
ratio will flow through the resistor, allowing the measurement of AC current.
For example, if the CT has 3000 turns and the terminal resistor is 100Ω,you can calculate the current using the formula:
Ｉ＝ ＶＲ×

Ｎ

＝

３．３ ×
１００

３０００

＝ ９９Ａ

Ｖ is the peak voltage waveform observed on the oscilloscope.
Ｉ is the current between the oscillator and the transformer.
Ｒ is the terminal resistance value.
Ｎ is the number of turns of the CT.
Ensure the observed waveform is a continuous sine wave,
typically at a frequency of 10-20 kHz.
Any discontinuity in the waveform might indicate a phase loss in the three-phasepower supply or assembly issues.
At a rated output of 5kW, the peak output current should be approximately 140A.

６

１１．Internal Components list
１）Leakage Circuit BreakerFujiElectric
ＤＧ３３Ｃ

３０Ａ

３０ｍＡ２）Diode Bridge Rectifier
Sanrex ＤＦ６０ＢＡ８０３）ＩＧＢＴFujiElectric

２ＭＢＩ３００Ｕ２Ｂ－０６０４）Smooth Capacitor
Shizuki ＭＥＣ

６００Ｖ

１００μＦ５）Resonance capacitor board
Navio
３Ｂ８２３Ｊ－１２６）Current Sensor１
Shiina ＴＣＴ０６－Ａ１７）Current Sensor２
Ｕ＿ＲＤ ＣＴＬ－１６－ＣＬＳ８）Control Board
Navio ＡＰＢ－１２１１９）Cooling FAN
ＯＭＲＯＮ

Ｒ８７ＦＡ４Ａ８３Ｈ１０）Heat output Metertsuruga
TMRD-21 1mA FS7.5kW

７Navio A4DS20

１２５４３７６８4-φ5.5
信号入力端子台仕様
Operation Command＋

２COM

３Error(Photocoupler Collector)

４４-２０ｍA＋

５４-２０ｍA－Input

６

Power Meter＋

Output７

Power Meter－Output

８

No Connection

ＡInput220Top(240)

Ａ

１Ｂ

Ｂ

8520085(405)

SideRearFront

ＣＣ370

3phase AC200V input
High Frequency Output高周波出力中
内部温度異常出力過電流異常Ｒ

ＳＴＵＶＵＶ

ＤＤ251.630A Leakage Breaker

Signal I/O terminal

ＥＥ

Air Inlet
Air Outlet

Date2018,08,24

Draw

H.Ogihara

Inspect

Y.Ogihara

Approval

A.Ogihara

名Induction Heater

称Ｆ

図番

HRT-5K2-G01
ぺ－

N a v i o

ジＦ

11Navio A3DS20

１２３５４７６８Ａ

Ａ

TSURUGA TMRD-21

60

FS1mADC 7.5kW

4824Ｂ

Ｂ

3φ54860

24ｋＷ

24Ｃ24Ｃ

panel cut

ＤＤＥ

Ｅ

Date

18,08,24

Draw

H.Ogihara

Inspect

Y.Ogihara

Approval

A.Ogihara

名Meter称Ｆ

Draw Inspect

Change Datails

HRT-5K2-APM-G01

N a v i oぺ－Rev Date

図番ジ1Ｆ

1Navio A3DS20

１２３５４HRT-5K2７６８Induction HeaterＡＡ

FG connect
三相入力端子台

高周波出力端子RS

TUVUVUＢＢ

To connecting Transfomer

３ΦＡＣ２００V Power input
U

Max AC 18A

１ ２ ３ ４ ５ ６ ７ ８

1 2 3 4 5 6 7V
信号入力端子台仕様

1-2 ON as Heating ON
Operation command +COMＣ

１

運転指令＋

２

COM

３

発振器異常出力（フォトカプラコレクタ）

４４－２０ｍＡ＋

５４－２０ｍＡ－

６電力メーター＋

７電力メーター－８

未接続

To connecting Transfomer
VＣError output
3-2 ON as Error+Linear control input
４－２０ｍＡ-Twist pair

ＤＤ

Twist pair

ＥＥ

年月日

18,08,24

設計荻原

名
称

HRT-5K2 Wiring diagram

図番

HRT-5K2-W01

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