HC500 Heater Controller
Function description - amp measurement (-I)
HETRONIK GmbH
Heisinger Str. 12 D-87437 Kempten / Germany
phone: +49 / (0)831-56 58 59-30 fax: +49 / (0)831-56 58 59-39 e-mail: [email protected]
www.heatcontrol.com
HC500-function-I_en.docx / March 18, 2021
Table of contents
page 2/16 HC500 Function description - amp measurement (-I)
1 Table of contents
1 Table of contents 2
2 Important Safety Information (read before using products) 3
3 Introduction 4
4 HC-parameters 5
4.1 HC-write-parameter 5
4.1.1 Lowest expected channel-amp [Ichmin] 5
4.2 HC-read-parameter 5
4.2.1 Channel-amp [Ich] 5
5 Amp measurement 6
5.1 Output firing 6
5.2 Concept 6
5.2.1 Nominal amp / actual amp 8
5.3 ESPscan 9
5.4 Partial load break 10
5.4.1 Ichmin setup suggestion 11
5.4.2 Ichmin limits 11
5.4.3 Natural amperage variation of cold vs. hot ceramic and quartz heaters 12
5.4.4 Amps of IR-lamps 13
5.5 Triac failure 15
6 HMI page example 16
Important Safety information
HC500 Function description - amp measurement (-I) page 3/16
c a u s e d e a t h o r
s e r i o u s i n j u r y
h i g h v o l t a g e
2 Important Safety Information (read before using products) To read and fully understand this document is prerequisite to ensure correct and safe operation of this equipment. In general
• proper shipping
• proper handling,
• professional installation by qualified personnel,
• professional master programming by qualified personnel,
• professional service and maintenance by qualified personnel are necessary for the correct and safe operation of this equipment. The use of these products must be limited to technically qualified personnel with the proper education and experience to design, install, and maintain complex high voltage (and/or high current) automated control systems. Technically qualified personnel are, for example:
• project and design personnel for electrical control panels and cabinets
• high voltage automated control system engineers or programmers
• electricians and electric control panel builders
• service technicians, all who know the applicable electrical codes and regulations and can properly apply this knowledge in the design of complex high voltage (and/or high current) automated control systems.
Unqualified personnel do not possess the ability to properly interpret the handling and installation information in the product documentation and therefore must not be responsible for
the installation or use of these products.
For each specific installation of this product all applicable safety regulations and industry “best practices” must be observed.
These products operate under high voltage. Improper handling of these products may result in death, series injury, and/or the loss of property.
Introduction
page 4/16 HC500 Function description - amp measurement (-I)
3 Introduction
This document describes amp measurement of all HC500 devices with "-I" in the product name:
• output-cards (OC), o exception all OCs with 6 channels
• output-modules (OM)
• output-unit-ampmeter (OUI) for the output-unit (OU) For a smoother readability and simplification, in the following we will partly only refer to OC. "-I" stand for
• amp measurement of each channel
• power-circle failure detection (fuse, triac or SSR, cable and heater)
To understand this document knowledge of the HC500 Function description - basics is essential.
HC-parameters
HC500 Function description - amp measurement (-I) page 5/16
4 HC-parameters
4.1 HC-write-parameter
4.1.1 Lowest expected channel-amp [Ichmin]
HC-parameter name short occurrence
lowest expected channel-amp Ichmin 1 x each channel
4.2 HC-read-parameter
4.2.1 Channel-amp [Ich]
HC-parameter name short occurrence
channel-amp Ich 1 x each channel
Amp measurement
page 6/16 HC500 Function description - amp measurement (-I)
5 Amp measurement
5.1 Output firing The HC500 power outputs on output-cards (OC) and output-modules (OM) as SSRs controlled with output-units (OU) are normally (= in normal operation) burst fired with full sinusoid waves.
1 full sinusoid wave is 1%. and 100 full sinusoid waves are 100% output-value [OV%]. Example for 25% OV% at 50 Hz:
5.2 Concept
For cost and space saving reasons, more than one channel is measured with one amp-measurement transformer only
via a multiplexed amp measurement routine:
0 s
1 2 3 4 255...24
0.1 s 0.2 s 0.3 s 1.9 s 2.0 s
heater
outputs
power switches
(triac)
power switch
fuses
amp-measurement
transformer
OC
A standard shop floor amp meters may not be able to show the correct effective amp.
Amp measurement
HC500 Function description - amp measurement (-I) page 7/16
All but the channel to measure are turned OFF and the amp is measured:
(Schematic only. Depends on OC, OM, and OU model.)
___ “amp scanning” after heating-ON Immediately after heating-ON with system-control [SC] bit 0 or 3 = "1" HC500 Function description - basic all active channels are measured in fast succession (one after another), without any time delay between the single measurements = amp scanning.
“refresh amp measurement” at heating-ON When heating is ON, every 10 seconds one channel (of one phase) is amp measurement. 10 seconds after the last channel is measured, a measurement is performed with all channels OFF to detect a short triacI . chapter 5.5, Triac failure, page 15 Depending on the OC, OM and OU channel qty. any of the max. 12 channels of a phase are measured every max. 130 second:
channel 1
OV% = 96 %
channel 2
OV% = 25 %
channel 3
OV% = 75 %
channel 4
OV% = 100%
channel 1:
channel 2
channel 3
channel 4
10 smax.
CH 12no CHCH 2 10 s CH 2 10 sCH 1
If a fast failure detection at a specific moment is needed, simply heating-OFF and - ON again to trigger amp scanning.
Amp measurement
page 8/16 HC500 Function description - amp measurement (-I)
5.2.1 Nominal amp / actual amp
With exception of output-value [OV%] = 100 %, the measured channel-amp [Ich] is not the actual amp, but the nominal amp of the heater/s. For example the channel-amp [Ich] of a 500 W / 230 V heater result in 2.2 A with output-values [OV%] 0 …100 %.
For OCs without -SL only (not for IR-lamps):
The channel-amp [Ich] is the nominal amp of the heater/s, not the actual amp of the heater/s.
When heating-ON, but OV% = 0%, [Ich] is measured anyhow.
Amp measurement
HC500 Function description - amp measurement (-I) page 9/16
5.3 ESPscan
For processes with short heating-ON times (< 10 seconds) of mainly IR-lamps, “amp scanning” can be triggered at heating-OFF to know if the power circles (fuse, triac, cable, heater) have errors. I.e. if bits in the error-status-power-circle [ESP] are “1". HC500 Function description - ESPscan
Amp measurement
page 10/16 HC500 Function description - amp measurement (-I)
5.4 Partial load break
Thanks to the channel-amp measurement it is possible to know if one heater of more heaters wired in parallel at the same OC-output fail.
For this function the lowest expected channel-amp [Ichmin] must be defined for each channel. If the channel-amp [Ich] is lower than the expected channel-amp [Ichmin], then error-status-power-circle [ESP] bit 3 = "1"
Extract from HC500 Function description - basics:
bit bit = "1" if
0 heater/wire broken
1 fuse blown
2 power switch (triac) cannot be turned OFF = shorted triac
3 amp to low (channel-amp [Ich] is lower than lowest expected channel-amp [Ichmin])
4 ---
5 one or more phases are missing
6 ***
7 not 49...51 or 59...61 Hz
A
Amp measurement
HC500 Function description - amp measurement (-I) page 11/16
5.4.1 Ichmin setup suggestion
Suggestion for value to input for lowest expected channel-amp [Ichmin]:
Example 1) 2 heaters with 1'000 W at 230 V Ichmin = 1'000 + (1'000 / 2) = 1'500 W / 230 V = 6.5 A Example 2) 5 heaters with 500 W at 480 V Ichmin = 4 x 500 + (500 / 2) = 2'250 W / 480 V = 4,7 A Example 3) 8 heaters with 2'000 W at 400 V Ichmin = 7 x 2'000 + (2'000 / 2) = 15'000 W / 400 V = 37.5 A
5.4.2 Ichmin limits
If channel-amp Ich < Ichmin a failure is indicated. Default Ichmin values and min. to input values:
with acronym in product name -V2
output-cards (OC) 0.8 A 0.3 A
output-modules (OM) 0.8 A ---
output-unit (OU) with output-unit-ampmeter/s (OUI)
2.0 A
1/2 1/2heaters 111
Ich
Ichmin
Amp measurement
page 12/16 HC500 Function description - amp measurement (-I)
5.4.3 Natural amperage variation of cold vs. hot ceramic and quartz heaters
The amperage ofcold vs. a hot ceramic and quartz heaters differ by 5%. Another 2% of amperage variation must be taken into consideration when a heater is older or at end of life. So the natural amperage variation is already 7%. One failed heater in a group of 10 heaters
is 10 %. The remaining 3 % amp change at partial load break may be too little to decide for sure if a heater is broken or not.
5.4.3.1 Voltage variation influence on amp measurement
The channel-amps [Ich] change with fluctuating power voltage. With help of the voltage-unit (VU) constant channel-amp [Ich] is obtained. "Function description - voltage unit (VU)"
A
7 % amp natural amp difference
1 of 10 heaters
= 10% amp
difference
More than 8 heaters should not be operated in parallel at the same channel, if a failure single heater must be detected.
The voltage-unit (VU) should be used if more than 4 heaters are operated in parallel at the same channel and if a failure of a single heater must be detected. For more than 2 IR-lamps please contact us.
Amp measurement
HC500 Function description - amp measurement (-I) page 13/16
5.4.4 Amps of IR-lamps
The channel-amp [Ich] of IR-lamps (halogen, tungsten, NIR, short wave,...)
depend on the temperature of the lamp coil. Inrush current of a cold IR-lamp:
The amp decreases as the temperature of the filament increases. For IR-lamps we have OCs with softSTART/light to reduce the amp peak. HC500 Function description - softSTART(-S) / softSTARTlight (-SL):
Amp measurement
page 14/16 HC500 Function description - amp measurement (-I)
The amp variation depends on the IR-lamp type, the manufacturer, the voltage and the wattage. For example:
output-value [OV%] channel-amp [Ich]
1 % = coil is relatively cold 7,3 A
2 % 6,5 A
3 % 5,6 A
5 % 5,0 A
7 % 4,6 A
10 % 4,4 A
15 % 4,1 A
20 % 3,9 A
30 % 3,6 A
50 % 3,3 A
70 % 3,1 A
100 % coil is hot 2,8 A (= 650 W / 230 V)
We have measured hundreds of IR-Lamps and found a formula that deliver a nearly constant corrected channel-amp [Ich]. This allows to control 2 IR-lamps in parallel at an OC-output and detect if one IR-lamp is broken. For more than two lamps in parallel at 1 OC-output pls. get in contact with us. Corrected channels amps are standard for all OC2 with firmware 3 and newer. Channel amp correction can (but should not) be disabled with output-card-control [OCC] bit 2.
Amp measurement
HC500 Function description - amp measurement (-I) page 15/16
5.5 Triac failure
In case a triac is defective (= short circuit), the triac cannot be controlled and the heater/s stay continuously ON.
For one cycle of the multiplexed ampt measurement, all channels are switched OFF. If the measured amp is not 0 A, at least one triac is short circuit. In this case all bits 2 of error-status-power-circle [ESP] of a phase are set to "1". HC500 Function description - basics: "ESPs of all channels" - because with a multiplexed amp measurement, it is impossible to know for sure which OC-output or which OC outputs have a short circuit triac. If only one triac is short circuit, the triac of the channel showing the correct channel amp [Ich] is defective.
In seldom cases a triac can be half short circuit
, so that only half of the channel-amp [Ich] is measured.
power switches
(triac)
power switch
fuses
amp-measurement
transformer
OC
2 A 2 A + 2 A = 4 A
2 A
2 A + 2 A = 4 A
2 A + 2 A = 4 A
2 A + 2 A = 4 A2 A
2 A
2 A
2 A
always ON = always 2 A
channel amp [Ich]for
example
To prevent fire, the power voltage to the output-card (OC) should be turned OFF in case a triac failure occurs.
Only ORIGINAL fuses protect a triac best possible to be destroyed with short circuit at OC-outputs. ORGINAL fuses are only available from HETRONIK
page 16/16 HC500 Function description - amp measurement (-I)
6 HMI page example
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6
2.6 1.3
2.6 2.6
2.6
2.6
2.6
2.6
2.6
2.6
show failure details
channel amps [Ich]
If background = red, then failure.
measure all amps again system-control [SC] bit 0 = and again
page with error-status-power-circles [ESP]
Nominal amp of the heaters, not the actual maps (except when the control value [OV%] is 100%).
