Smitec HELCON 10 Series Kurzanleitung

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 1

Smitec S.p.A., viale Vittorio Veneto 4, 24016 San Pellegrino Terme (BG), Italy, www.smitec.it

Installation, use and maintenance manual

CONTROL MODULE IR LAMPS

HELCON 11XX SERIES

BEFORE USING THE MODULES OF THE HELCON 11XX SERIES, YOU MUST READ

THIS INSTALLATION AND USE MANUAL CAREFULLY AND FOLLOW ALL THE INDI-

CATIONS TO GUARANTEE THE MAXIMUM SAFETY

The technical data and the drawings in this manual might have been modified later; always

refer to the latest version.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 2

Summary

1 Preface ....................................................................................................................................................... 3

1.1 Main differences between the HELCON 10XX and HELCON 11XX series ........................................ 3

2 General warnings ...................................................................................................................................... 4

3 Safety instructions .................................................................................................................................... 6

3.1 General information ............................................................................................................................ 6

3.2 Precautions during handling and assembly ........................................................................................ 6

3.3 Precautions against the risk of electrocution ...................................................................................... 7

3.4 Precautions against contact with hot parts ......................................................................................... 7

3.5 Residual risks ...................................................................................................................................... 7

4 Technical data ........................................................................................................................................... 8

4.1 Environmental characteristics ............................................................................................................. 8

4.2 Electrical characteristics ..................................................................................................................... 9

4.2.1 Lamp pilot outputs ....................................................................................................................... 9

4.3 Mechanical specifications ................................................................................................................. 10

4.3.1 Weight ....................................................................................................................................... 10

4.3.2 Dimensions ............................................................................................................................... 10

4.4 Order codes ...................................................................................................................................... 11

4.5 Accessories ....................................................................................................................................... 11

5 Installation and commissioning ............................................................................................................ 12

5.1 Preliminary operations ...................................................................................................................... 12

5.2 Mechanical assembly ........................................................................................................................ 13

5.2.1 Positioning and fixing ................................................................................................................ 13

5.3 Connections ...................................................................................................................................... 16

5.3.1 Power supply - J1 ..................................................................................................................... 17

5.3.1.1 Connection scheme ........................................................................................................... 18

5.3.1.2 Electromagnetic compatibility ............................................................................................ 20

5.3.2 Fieldbus - Connector J2 and J3 ................................................................................................ 20

5.3.3 24VDC input power supply - J4 connector ................................................................................ 22

5.3.4 24VDC power supply - J5 connector ........................................................................................ 23

5.4 LEDs ................................................................................................................................................. 24

5.4.1 Fieldbus status .......................................................................................................................... 24

5.4.2 Auxiliary power supply status .................................................................................................... 25

5.5 Addressing ........................................................................................................................................ 25

5.5.1 Manual addressing .................................................................................................................... 26

5.5.2 Automatic addressing ............................................................................................................... 27

5.6 Power output ..................................................................................................................................... 28

5.6.1 HELCON 1108 .......................................................................................................................... 28

5.6.2 HELCON 1110 .......................................................................................................................... 29

6 Operation and diagnostics ..................................................................................................................... 30

6.1 Theory of operation ........................................................................................................................... 30

7 Storage ..................................................................................................................................................... 33

8 Firmware upgrade ................................................................................................................................... 34

9 Maintenance ............................................................................................................................................ 35

9.1 Fuse replacement ............................................................................................................................. 36

9.2 Replacement of the SSR module ...................................................................................................... 36

9.3 Periodic maintenance - Tightening of the fuse holder terminals and power dividers ........................ 38

10 Disposal and demolition ....................................................................................................................... 40

11 Analytical index ..................................................................................................................................... 41

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 3

1 Preface

This manual provides all necessary information for the installation, use and maintenance of the control module

IR lamps HELCON 11XX series.

The instructions included in this manual are addressed to the following professionals:

The present instructions must be made available to all the above individuals.

1.1 Main differences between the HELCON 10XX and HELCON 11XX series

The substantial difference is an improvement in the lighting technology of the lamp outputs which works opti-

mally even with power supply with distorted sinusoidal voltage. To obtain this functional improvement of the

device, the SSR modules of the HELCON 10XX series and of the HELCON 11XX series are not interchange-

able with each other.

Furthermore, for the purposes of electrical safety, the LED indicators and the rotary switch for setting the ad-

dress are accessible from the outside without the need to open the protective casing.

User User is a person, a company or an institution that buys the equipment and

uses it for the purposes it was designed for.

User/operator User or operator is a person authorized by the user to operate on the equip-

ment.

Specialized personnel It refers to all persons with specific competence, able to recognize and avoid

the dangers deriving from the use of the equipment.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 4

2 General warnings

These assembly instructions are an integral part of the equipment, and must be kept for future reference until

it decomissioned.

The user should be informed that the present instructions reflect the state of the art at the moment when the

equipment was sold; they will remain fully acceptable despite subsequent upgrades based on new technical

update.

In order to make the manual consultation easier, the following symbols have been adopted:

DO NOT USE THE EQUIPMENT, NOR MAKE ANY INTERVENTION BEFORE INTE-

GRALLY READING AND UNDERSTANDING THIS MANUAL.

IN PARTICULAR, ADOPT ALL SAFETY PRECAUTIONS AND PRESCRIPTIONS INDICATED IN THIS

MANUAL.

THE EQUIPMENT MUST BE USED FOR PURPOSES DIFFERENT THAN THE ONES DESCRIBED IN

THIS MANUAL; SMITEC S.p.A. SHALL NOT BE HELD RESPONSIBLE FOR ANY DAMAGES, INCON-

VENIENCES OR ACCIDENTS DUE TO THE NON-COMPLIANCE WITH THESE PRESCRIPTIONS.

Indication of “PROHIBITED ACTION”.

The symbol “DANGER” is used when non-compliance with the prescriptions or misuse may

cause serious injuries.

The symbol “DANGER FROM HOT SURFACES” is used when non-compliance with the

prescriptions or misuse may cause serious injuries.

The symbol “DANGER FROM ELECTRICAL SHOCK” is used when non-compliance with

the prescriptions or misuse may cause serious injuries.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

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The safety prescriptions aim at establishing a series of behaviors and obligations to be complied with, while

performing the activities described later on in this manual.

These prescriptions constitute the prescribed method of operating the device, in a way that is safe for person-

nel, equipments and environment.

The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective gloves must be

worn.

The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective glasses must be

worn.

Indication of “INFORMATION OF PARTICULAR RELEVANCE”.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 6

3 Safety instructions

3.1 General information

3.2 Precautions during handling and assembly

Do not install or use the equipment before integrally reading and understanding this manual.

In case of difficulties of interpretation, contact SMITEC technical service.

It is absolutely forbidden to use the equipment for different purposes than the ones de-

scribed in this manual. The technical data and the drawings in this manual might have been

modified later; always refer to the latest version. All upgrades can be requested to SMITEC

S.p.A. directly.

Make sure that the personnel is qualified and adequately informed about the risks he may

run and how to avoid them.

The use of the HELCON 11XX series IR lamp control modules is authorized only after clas-

sification of the operating area of the final machinery and verification of safety levels, which

must be congruent with the safety levels of the unit.

Metal components and sharp surfaces may cause cuts and tears. In case of contact, be very

careful and wear the personal protection equipment.

Use adequate tools during the assembly, in order to avoid crushing or abrasions.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

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3.3 Precautions against the risk of electrocution

3.4 Precautions against contact with hot parts

3.5 Residual risks

The main power connector is subjected to high voltages during module operation; pay at-

tention (danger of electrocution).

During all phases of installation and maintenance of the equipment, disconnect it safely from

the power supply network. Electrolocution risk.

Some components of the apparatus (for example: the aluminum heatsink) are made of con-

ductive materials. They must be connected securely to the protective conductor (PE) using

the appropriate terminals, to avoid risk of electrolocution.

Never use the device partially or totally disassembled. Danger of electric shock and / or

damage to persons and property.

The parts of the apparatus can reach an extremely high temperature in operating mode or

post-operation; take particular care not to touch the parts of the equipment in these cases,

or use special protections and precautions during handling: HOT SURFACE, RISK OF

BURNS.

By using the device in the construction of a machine, the manufacturer must take all pre-

cautions to avoid the operator's contact with the hot parts, to avoid the risk of burns.

The apparatus generates an electromagnetic field during operation. Danger for people with

pacemakers, metal prostheses or hearing aids.

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 8

4 Technical data

4.1 Environmental characteristics

All the technical information reported in this section are consistent with the hardware con-

figuration of the HELCON module produced at the date of writing of this document. With the

aim of technologically improving or updating the product, SMITEC S.p.A. reserves the right

to change the technical characteristics of the HELCON module without prior notice.

Operating temperature

Model: HELCON 1110

Code: KZ010605

0°C ÷ +45°C

Operating temperature

Model: HELCON 1108

Code: KZ010604

0°C ÷ +50°C

Storage temperature -20°C ÷ +70°C

Maximum altitude

1000 m a.s.l. at nominal output current

2000 m a.s.l. with current derating

Output current derating as a function of

altitude

Degree of protection of the enclosure IP65

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 9

4.2 Electrical characteristics

4.2.1 Lamp pilot outputs

Main power supply voltage 400VAC -10% ÷ 480VAC +5%

Type of power supply 2PH 50/60 HZ

Maximum short-circuit current 5 kA at the point of installation

Current main power consumption

Model: HELCON 1110

Code: KZ010605

63.8A

Current main power consumption

Model: HELCON 1108

Code: KZ010604

60.0A

Power input main power

Model: HELCON 1110

Code: KZ010605

25.5kW

Power input main power

Model: HELCON 1108

Code: KZ010604

24.0kW

Auxiliary power supply voltage 24V DC -15 ÷ +20%

Current consumption of auxiliary power supply 0.5A

The input current strongly depends on the impedance of the network; the values shown refer

to a perfectly sinusoidal network with zero generator impedance. In real cases there is a re-

duction in the input current value which can exceed 30%.

Type of electric load Halogen infrared lamps

Utilization category AC-55b (according to EN 60947-4-3)

Current max. deliverable on a single output 7.5A RMS

IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN

Ver. 1.02 10

4.3 Mechanical specifications

4.3.1 Weight

The following table shows the weight of the various models:

4.3.2 Dimensions

External measurements of the only device:

Type Weight (kg)

KZ010604 14.1 kg

KZ010605 15.0 kg

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