IR lamp control module - HELCON 11XX series -
Installation, use and maintenance manual - EN
Ver. 1.02
30
6 Operation and diagnostics
The HELCON 11XX series modules are designed for the control of infrared halogen lamps. Each module al-
lows the piloting of 8 (HELCON 1108) or 10 lamps (HELCON 1110), with control of the power level supplied to
each lamp.
The electronics are housed inside a sturdy metal case with IP65 protection rating, suitable for “visible” mounting
directly on the machine. It is equipped with a watertight inspection door that can be opened only by means of
a special key (supplied). The wiring is ensured by robust removable connectors with mechanical retention,
making it easier to replace a defective unit.
An aluminum heatsink mounted on the back of the device allows the thermal dissipation of the module, without
the use of additional “fanless” fans. The absence of weary elements increases the reliability of the device.
The device works with two-phase alternating power supply, and the power outputs are made by electronic
switches (TRIAC). Each power output is mounted on a separate module, easily replaceable in case of damage.
The protection fuses of the outputs are housed inside each module, making the installation extremely compact.
The interfacing with the process controller is guaranteed by a proprietary FLxIO real-time fieldbus based on
RS485. The bus is wired using M12 connectors, allowing standard pre-printed cables to be used.
The internal management electronics also allows the following features:
• Compensation of the mains voltage (the output power output is made independent of the supply voltage).
• Diagnostic check of the lamps.
• Reading of the resistance of the lamps.
• Checking the internal temperature of the device and its diagnostics.
6.1 Theory of operation
The Helcon 11XX series module, specifically designed for the control of infrared halogen lamps, uses a two-
phase power input and, through the internal firmware and the parameters sent to it by the external process con-
troller, appropriately activates the power outputs consisting of static semiconductor relays. (TRIAC). Each pow-
er output powers the load consisting of an infrared lamp in the power range indicated in the technical
specifications and is independent from the others.
The switching of the power output occurs in correspondence with the passage on 0V of the alternating input
voltage technically called "Zero Crossing"; this synchronization with the mains voltage is necessary to create
the minimum harmonic distortion possible on the mains due to the absorption of the load.
When the input voltage passes to 0V, and therefore at each half-wave of the alternating voltage, the electronics
of the Helcon 11XX module sends an ignition command to the TRIAC semiconductor devices that must activate
their load.
For reasons of thermal dissipation, the ignition command cannot last as long as the length of the half-wave of
the alternating voltage and is therefore limited in time. Since the TRIACs have the ability to remain ignited once
a sufficient amount of current flows inside them, the ignition command can be interrupted without the output
