Short wave Infrared Lamps_IR Applications

USER’S MANUAL Rev. 01/2002 APPLICATION NOTES INFRARED 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 CD Automation S.r.l. Via F.lli Cervi, 42/44 20020 – Cantalupo di Cerro Maggiore (MI) – Italy Tel +39 0331 533512 – Fax +39 0331 533516 e-mail: [email protected] web: www.cdautomation.com C.D. Automation Srl Infrared notes infrared notes 01/2002 issue Application Notes for Infrared Index: 1. INFRARED HEATING TECHNIQUES 2 2. INFRARED HEAT MEETS ALL REQUIREMENTS 3 3. DIFFERENT TYPES OF INFRARED 4 4. ELECTRONIC PANEL 6 5. INFRARED APPLICATIONS 7 6. CURE OF INRUSH CURRENT ON SHORT AND ULTRASHORT IRSW 8 7. SINGLE CYCLE AND BURST FIRING 13 8. PEAK OF CURRENT AS FUNCTION OF NUMBER OF BURST FIRING CYCLES 15 9. BURST FIRING AND SINGLE CYCLE IN CONTINUOUS PROCESS 22 1 C.D. Automation Srl Infrared notes 1. INFRARED HEATING TECHNIQUES Heating plays a central role in the forming and processing of: - plastic - paper - glass - wood - metals - printing - electronics - food - chemical and farmaceutical - ceramic - air conditioning - tobacco and others applications. 2 C.D. Automation Srl Infrared notes 2. INFRARED HEAT MEETS ALL REQUIREMENTS - Heat transfer is easy. It requires no contact with the material and no intermediate such as air or water. - High power can be transmitted. Foils, plates and other shapes are heated in seconds. - The heating process fits in easily with the manufacturing process. - The process is economical because the heat loss is small as the heating effect is confined to the material to be heated. - Infrared rediation is safe and can be easily switched ON/OFF. 3 C.D. Automation Srl Infrared notes 3. DIFFERENT TYPES OF INFRARED The temperature of emitter determines the special distribution of the wavelengths. See figure 1, with decreasing temperature the spectrum shifts to the longer wavelengths. The position of the peak intensity in the spectrum gives the emitters their names: Short wave: maximum emition ~ 1,3µm Medium wave: maximum emition ~ 2,3 ÷ 3,4µm UV 250 200 Visibile light Radiation Intensity (relative units) Long wave: maximum emition ~ 3 ÷ 5µm IR-A IR-B IR-C Short wave Medium wave Long wave Halogen 2600°C Short Wave 2200°C 150 Fast Response Medium Wave 1600°C Carbon 1200°C 100 Medium Wave 900°C 50 0 0 1 2 Wavelength (µm) 3 Figure 1. Infrared spectra of different emitters 4 4 5 C.D. Automation Srl Infrared notes Just like visible light, part of the broad spectrum of the IR radiation is reflected from the surface of the material, part is absorbed within the material and part penetrates through the material. The reflected component is usually very small. The component of the rediation spectrum which is absorbed is that which coincides with the wavelength of the molecular oscillation in the material. When the radiation is absorbed, it gives up its energy to the molecules so that the material is heated. Short waveform Medium waveform Long waveform Figure 2. Penetration of different IR waveform 5 C.D. Automation Srl Infrared notes 4. ELECTRONIC PANEL CD Automation has developed a product range of Thyristor unit to drive IR. It’s possible to drive power with different types of firing modes: Single Cycles, Burst Firing and Phase Angle. In the next pages will be described the different techniques. CD Automation can provide a complete panel including: - cabinet - thyristor unit - temperature or humidity controller with Auto/Manual command. The temperature can be detected with thermocouple or pyrometer - an input for speed can be the main setpoint or a trim set of the power 6 C.D. Automation Srl Infrared notes 5. INFRARED APPLICATIONS We have metioned that there are different types of infrared: short, medium and long waveform. Let’s see in particular the different kinds of infrared: a) short waveform: peak current ~ 7 times I nominal. Attention must be payed in sizing the thyristors b) ultrashort waveform: peak current ~ 16 times I nominal. Attention must be payed in sizing the thyristors c) medium waveform: I peak equal to I nominal. No attention must be payed to peak current d) fast medium: These elements are in thungsten like short type and the peak current is lower but the necessary time to be heated is longer and this stresses the thyristors e) long: I peak equal to nominal. No attention must be payed in sizing the thyristors f) In car industry and in other special applications the short IRW are supplied with very low voltage compared with the nominal one to change the IRW penetration. Cure must be used for these applications for current sizing of thyristors. In fact, must be used the normal precaution for short waveform plus extra precaution for voltage supply lower than the nominal that causes a lower peak but a very long overcurrent that stresses the thyristors. For sizing contact CD Automation, it will be necessary to collect more informations from the supplier of the IRW short. 7 C.D. Automation Srl Infrared notes 6. CURE OF INRUSH CURRENT ON SHORT AND ULTRASHORT IRSW When there is inrush current, the first technique that an engineer can adopt is to limit it with Current Limit and Phase Angle firing. This technique cannot be used for the following reasons: The current with Phase Angle and Current Limit is not really limited for the first 5 periods (100msec). In fact, Current Limit function is an electronic circuit that has a delay of ~ 100msec due to the current transformer inertia and passive components. See the graph below. 20 15 10 5 0 -5 -10 -15 -20 -25 Figure 3. How Current Limit works: the graph represents the current absorption of a cold IR lamp starting with CL (10V 50ms) 8 C.D. Automation Srl Infrared notes To reduce this phenomenon is used a long soft start. Phase Angle technique with Current Limit cost more than Single Cycle technique, specially for 3 phase loads. In addition, the overload current remains for a longer time than with no Current Limit. This can be explained by the fact that short infrared are cold resistances. When those elements are colds there is the maximum current with low resistance. Increasing the temperature this will increase the resistance too. If we reduce the voltage, we reduce the energy supplied and it will take more time to heat itself. In the next pages we must keep in mind this phenomenon. See the graphs below. 9 C.D. Automation Srl Infrared notes 20 15 10 5 0 -5 -10 -15 -20 -25 Figure 4. The graph represents the current absorption of a cold IR lamp with Current Limit (10V 500ms) 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 Figure 5. The graph represents the current absorption of a cold IR lamp without Current Limit As you can see in the above graphs, with Current Limit the inrush current remains high for a longer time. 10 C.D. Automation Srl Infrared notes Let’s see the technical data. Measure mode IR lamp without CL IR lamp with CL Min/Max Min/Max Period 20ms 20ms Frequency 50.1Hz 50.1Hz Pos. Pulse Width 10.4ms 10.4ms Neg. Pulse Width 9.52ms 9.66ms Rise Time 5.95ms 5.93ms n/a 6.77ms Pos. Duty Cycle 52.31% 51.73% Neg. Duty Cycle 47.69% 48.27% Pos. Overshoot 0.00% 0.00% Neg. Overshoot 0.00% 0.00% Peak to Peak 44.4V 37.2V Amplitude 44.4V 37.2V High 20.9V 17.7V Low -23.5V -19.5V Maximum 20.9V 17.7V Minimum -23.5V -19.5V -227mV -235mV Cycle Mean 1.69V 1.08V RMS 3.18V 3.03V AC RMS 3.17V 3.02V Cycle RMS 14.5V 12.5V 14V 12.3V 3.82s 3.84s Fall Time Mean Cycle AC RMS Burst Width 11 C.D. Automation Srl Infrared notes Test with IR lamps using a CD3000 with Current Limit. Single Cycle 1 POWER Oscilloscope Inom I peek Clamp power meters I RMS I Peek I Avg Ilimit = Inom 100 90 80 70 60 50 40 30 20 10 1 Single Cycle 1 POWER 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.6 7.8 8 8.4 8.6 9.4 10 15 41 Oscilloscope Inom I peek 4.86 4.69 4.61 4.41 4.22 4.02 3.78 3.46 3.21 2.8 I RMS 7.22 7.39 7.64 7.87 8.04 8.35 8.75 9.42 10.3 12.57 4.33 4.01 3.68 3.46 3.02 2.75 2.35 1.94 1.6 1 Clamp power meters I Peek I Avg Ilimit = 1.5 x Inom 100 90 80 70 60 50 40 30 20 10 1 Single Cycle 1 POWER 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.6 8 8 8.4 8.6 9.5 10 15 40 Oscilloscope Inom I peek 4.86 4.69 4.61 4.41 4.22 4.02 3.78 3.46 3.21 2.8 7.22 7.39 7.64 7.87 8.04 8.35 8.75 9.37 10.5 12.58 4.37 3.98 3.68 3.46 3.05 2.75 2.35 1.97 1.6 1 Clamp power meters I RMS I Peek I Avg Ilimit = 2 x Inom 100 90 80 70 60 50 40 30 20 10 1 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.4 7.3 7.6 8.1 8.24 8.4 8.6 9.4 9.8 15.1 41 12 4.86 4.69 4.61 4.41 4.22 4.02 3.68 3.45 3.13 2.8 7.3 7.41 7.64 7.87 8.04 8.36 8.9 9.52 9.98 12.6 4.33 4.01 3.68 3.46 3.02 2.75 2.12 1.63 1.25 0.92 C.D. Automation Srl Infrared notes 7. SINGLE CYCLE AND BURST FIRING The technique of Single Cycle is the most used to drive infrared short waveform. Single Cycle is the fastest mode with zero crossing to control in non-continuous mode the load power. For example: 25% of power = 1 cycle ON + 3 cycles OFF 50% of power = 1 cycle ON + 1 cycle OFF 75% of power = 3 cycles ON + 1 cycle OFF To have more details see firing modes in application notes. This firing technique is important for infrared short because inrush current is present in the following cases: a) when the load is cold and is switched ON for the first time b) when controlling the power the load is switched OFF and after a time it is switched ON. During the OFF time the IRSW element become cold (due to their low inertia) and when it is switched ON again there is a peak of current. 13 C.D. Automation Srl Infrared notes The best technique is to reduce at the minimum the OFF time providing to be able to control the power. The firing mode able to do this is Single Cycle. In the graph below is possible to see the overcurrent as a function of the power demand with Single Cycle. To reduce the thyristor’s stress, the unit starts working at 10% because at 1% of power demand the peak of current is 2,75 I nom. This means that thyristor unit for IRSW starts working when input signal is 10% of the power. If with input 0÷10V the signal is 1V, the thyristor doesn’t go in conduction. This is because normally the thyristor is controlled by a temperature controller (closed loop) and if the process is well designed the power demand is ~ 60%. If is necessary to use a power below 10%, inform CD Automation to have the units working also below 10% of power demand. 3 2,5 2 Inom 1,5 I peek I RMS 1 I Avg 0,5 0 100 90 80 70 60 50 40 30 20 10 1 Figure 6. The overcurrent as a functin of power demand with Single Cycle 14 C.D. Automation Srl Infrared notes 8. PEAK OF CURRENT AS FUNCTION OF NUMBER OF BURST FIRING CYCLES To demonstrate that OFF time must be as short as possible to reduce the peak of current, look at the graph below. There are 4 curves using the 50% of power demand: Curve 1 – 1 cycle ON + 1 cycle OFF at 50% of power Curve 2 – 2 cycles ON + 2 cycles OFF at 50% of power Curve 3 – 3 cycles ON + 3 cycles OFF at 50% of power Curve 4 – 4 cycles ON + 4 cycles OFF at 50% of power 15 C.D. Automation Srl 16 Infrared notes Figure 7. Peak of current as a function of the power C.D. Automation Srl Infrared notes In figure 7 (previous page) is possible to see that at 10% the current with 1 cycle is lower than the current at 2, 3 or 4 cycles. This is because the OFF time is lower and the IRSW has not time enough to become cold. Measure mode Min/Max Period 19.9ms Frequency 50.3Hz Pos. Pulse Width 10.6ms Neg. Pulse Width 9.29ms Rise Time 6.39ms Fall Time n/a Pos. Duty Cycle 53.28% Neg. Duty Cycle 46.72% Pos. Overshoot 0.00% Neg. Overshoot 0.00% Peak to Peak 42.4V Amplitude 42.4V High 19V Low -23.4V Maximum 19V Minimum -23.4V Mean -253mV Cycle Mean 2.69V RMS 2.77V AC RMS 2.76V Cycle RMS 13.9V Cycle AC RMS 12.3V Burst Width 9.63s 17 C.D. Automation Srl Infrared notes 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 Figure 8. Behaviour of an IR cold lamp 18 C.D. Automation Srl Infrared notes Burst 1 POWER 100 90 80 70 60 50 40 30 20 10 1 Oscilloscope Inom I peek 7 7 7 7 7 7 7 7.4 7 7.6 7 7.8 7 7.8 7 8.4 7 8.7 7 10.08 7 18.6 Clamp power meters I RMS I Peek I Avg 4.74 7.62 4.2 4.56 7.72 3.98 4.43 7.84 3.68 4.26 8.07 3.5 3.98 7.27 2.72 3.79 7.6 2.42 3.56 7.98 2.04 3.28 8.53 1.64 2.95 9.3 1.18 2.49 11 0.8 n.m. n.m. n.m. Burst 2 POWER 100 90 80 70 60 50 40 30 20 10 1 Oscilloscope Inom I peek 7 7 7 7 7 7 7 7.2 7 7.6 7 8 7 8.2 7 8.8 7 9.4 7 11 7 20 Clamp power meters I RMS I Peek I Avg 4.66 6.65 4.17 4.6 6.81 4.6 4.35 6.91 3.5 4.2 7.13 3.25 4.01 7.35 2.83 3.8 7.62 2.5 3.63 8.05 2.02 3.4 8.57 1.5 2.97 9.5 1.22 2.5 11 1 n.m. n.m. n.m. 19 C.D. Automation Srl Infrared notes 25 20 15 10 5 0 -5 -10 -15 -20 -25 Figure 9. Peak with power 1% with cold lamp A 20 15 10 5 0 -5 -10 -15 -20 -25 Figure 10. Peak with power 10% with cold lamp A 20 C.D. Automation Srl Measure mode Infrared notes IR cold lamp A IR cold lamp B Min/Max Min/Max Period 220ms 3s Frequency 4.54Hz 333mHz Pos. Pulse Width 210ms 2.99ms Neg. Pulse Width 10.2ms 11.6ms Rise Time 6ms 6.4ms Fall Time n/a 2.99s Pos. Duty Cycle 95.37% 99.61% Neg. Duty Cycle 4.63% 0.39% Pos. Overshoot 0.00% 0.00% Neg. Overshoot 0.00% 0.00% Peak to Peak 44V 40.8V Amplitude 44V 40.8V High 20.5V 19.1V Low -23.5V -21.7V Maximum 20.5V 19.1V Minimum -23.5V -21.7V -233mV -243mV -5.57V -222mV 2.31V 1.08V 2.3V 1.05V Cycle RMS 4.22V 1.17V Cycle AC RMS 4.08V 1.05V 4.3s 6s Mean Cycle Mean RMS AC RMS Burst Width 21 C.D. Automation Srl 9. BURST FIRING Infrared notes AND SINGLE CYCLE IN CONTINUOUS PROCESS Infrared IRSW A + + Figure 11. Tunnel fournace for heating treatment In the figure 7 is shown a tunnel fournace for the heating treatment of product A (on the left). The product is moving on the conveyor at high speed to increase production. Let’s say that the product takes 5 seconds to go throught the tunnel and power demand is 50%. If cycle time (time ON + time OFF) is 20 seconds the ON time will be 10 seconds, then could happen that the product A will not be treated because the transit will be in OFF time. Now, if we use cycle time of 40msec (20msec ON + 20 msec OFF) we are sure that the product will be treated. CD Automation Thyristor units can be setted in power for a fixed speed value of conveyor and compensated for speed variations. If we twice the speed, then the power will also become double. 22