SICK HC8X Manual

TECHNICAL INFORMATION
HC8X
Heat Control
Installation
Operation
Maintenance

Technical Information
HC8X Heat Control
E-2 ©SICK AG · All rights reserved 8010043
Document Information
Copyright
Copyright 2013SICK AG
Printed in the Federal Republic of Germany
Editor
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch - Germany
Phone: [phone]
Fax: [phone]
Part No.: 8010043
Release: 1.1
Date: 2013-01

Technical Information
HC8X Heat Control
Basic Information
8010043 ©SICK AG · All rights reserved E-3
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch - Germany
Phone: [phone]
Fax: [phone]
EMail: [email protected]
Cusotmer Servcie
Your local representative will be glad to answer your questions and give you any support
required.
You will find our local subsidiary or agency at:
www.sick.com

Technical Information
HC8X Heat Control
Contents
E-4 ©SICK AG · All rights reserved 8010043
Contents
1 Product Description........................................................................................................... 14
1.1 Method of Operation of the Control Unit.................................................................. 14
1.2 Control Unit Design........................................................................................................... 14
1.2.1 Special Control Unit Configuration .............................................................................. 14
1.2.2 Schematic Block Diagram.............................................................................................. 15
1.3 HC8X Process Connection ............................................................................................ 16
1.4 Signaling................................................................................................................................ 16
2 Installation/Removal ......................................................................................................... 19
2.1 Selecting the Installation Location.............................................................................. 19
2.2 Installing the HC8X ........................................................................................................... 19
2.3 Removing the HC8X......................................................................................................... 20
3 Electrical Installation ........................................................................................................21
3.1 Overview of Installation Steps...................................................................................... 21
3.2 Connecting the Power Electronics Supply Voltage............................................... 21
3.3 Connecting the Heating Circuits .................................................................................. 22
3.3.1 Connecting Single-Phase Heating Circuits............................................................... 22
3.3.2 Connecting Two-Phase Heating Circuits................................................................... 22
3.3.3 Connecting Three-Phase Heating Circuits ............................................................... 23
3.4 Connecting the Temperature Sensors...................................................................... 23
3.5 Connecting the Optical Fibers ...................................................................................... 24
3.6 Connecting the Control Electronics Supply Voltage............................................. 25
3.6.1 Supply Voltage and Fuse Preselection, Primary Side.......................................... 25
3.6.2 Connecting the Supply Voltage.................................................................................... 25
4 Configuration and Addressing........................................................................................ 26
4.1 Preparations........................................................................................................................ 26
4.2 Overview ................................................................................. for Parameter Settings26
4.3 Parameter Setting with HC8XINIT.EXE under MS-DOS....................................... 26
4.3.1 "HC8XINIT.EXE" DOS Option Window........................................................................ 26
4.3.2 Configuration Query of HC8X with HC8XINIT.EXE................................................. 27
4.4 Parameter Setting Example with HC8XINIT.EXE under MS-DOS .................... 28
4.5 Configuring the Control Channel as a Follower ..................................................... 30
4.5.1 Example for "Channel Following" ................................................................................ 30
4.6 Final Steps ........................................................................................................................... 30
5 Start-up .................................................................................................................................. 31
5.1 Presetting the HC8X......................................................................................................... 31
5.1.1 Setting the HC8X Mode.................................................................................................. 32
5.2 Start-up of the Control..................................................................................................... 32
5.2.1 Start-up of the Measuring System PC....................................................................... 32
5.2.2 Start-up of the HC8X........................................................................................................ 33
5.3 Start-up of the Process................................................................................................... 33
5.4 Control Process.................................................................................................................. 34
6Temporary Shutdown ........................................................................................................ 35
6.1 Switching off the HC8X ................................................................................................... 35
6.2 Switching the HC8X on Again ....................................................................................... 35

Technical Information
HC8X Heat Control
8010043 ©SICK AG · All rights reserved E-5
Contents
7 Retrofitting / Conductor Bar Configuration ............................................................... 36
7.1 Retrofitting the HC8X........................................................................................................36
7.1.1 Retrofitting the HC8X with an Even Number of Channels..................................36
7.1.2 Retrofitting the HC8X with an Odd Number of Channels....................................38
7.2 Configuring the Power Bars ...........................................................................................39
8 Troubleshooting .................................................................................................................. 41
8.1 Power Electronics Overload Protection .....................................................................41
8.2 Primary-Side Fuses of the Control Electronics .......................................................41
8.3 Secondary-Side Fuses of the Control Electronics.................................................41
8.4 Automatic Over-Temperature Protection of 
Control Electronics ...........................................................................................................................42
9 Disposal ................................................................................................................................. 43
9.1 Disposal after Final Shut-Down ....................................................................................43
10 Technical Data / Annex.................................................................................................... 44
10.1 Dimensions / General Data...........................................................................................44
10.2 Electrical Data / Temperatures ....................................................................................45

Technical Information
HC8X Heat Control
E-6 ©SICK AG · All rights reserved 8010043
Introduction
Introduction
This documents provides instructions for:
Mounting and electrical installation
Start-up and shut-down
Operation, configuration and parameter setting
Retrofitting and troubleshooting
This document contains information on:
Safety warnings and recommendations that must be followed to ensure safe operation
and to maintain the control unit in a safe condition.
Contact partners and intended use
Environment and compliance
Method of operation and design of the control unit
The HC8X heat control is referred to as "HC8X" in the following.
Target groups:
The target groups of this document are persons with electro-technical training.
Mounting, electrical installation, servicing and replacement:
Electricians and service technicians
Start-up, operation and configuration:
Technicians and engineers
Information depth:
This document contains all information required for mounting, electrical installation and
start-up of the HC8X with the basic factory settings.
All these activities are explained step by step.
The configuration of the HC8X for the specific application usage is performed with the
DOS 6.22-oriented HC8XINIT.EXE utility program or with the Windows-oriented
SETHC8X.EXE utility program.
The warnings and safety notices summarized on the following pages are intended to sup-
plement, not supersede, the safety regulations valid in the individual countries.
Before start-up of the control unit:
Carefully read and observe the safety notices and warnings contained in this manual as well
as the relevant chapters on installation, start-up and operation of the control unit.
Before starting to work, inform yourself about the relevant regulations for preventing acci-
dents issued by the professional associations, the legal stipulations (safety regulations con-
cerning hazardous substances) and the standards.
Always observe all warnings and safety notices in the Manual!

Technical Information
HC8X Heat Control
Symbols Used
8010043 ©SICK AG · All rights reserved E-7
Used Symbols
Some information in this documentation is specially highlighted for faster access to this in-
formation.
Warning!
A warning protects from bodily injuries or the HC8X heat control from serious damage.
Always read and follow the warnings carefully.
Electrical hazard!
Warning of the danger of death by electrical shock when not complying with the relevant VDE
and safety and control unit directives.
Always read and follow the warnings carefully.
Note A note provides information on special characteristics.
Explanation An explanation provides background knowledge on technical interdependencies.
Recommendation A recommendation is an aid to the optimum performance of an activity.
Tip A tip explains setting options for the SETHC8X.EXE user interface.
Basic setting Marks a section in which the values of the basic factory setting are listed.
This symbol marks a section in which operating steps with the user interface of
HC8XINIT.EXE or SETHC8X.EXE are described.
This symbol refers to supplemental technical documentation.
Here, you have to do something. This symbol marks single-step action instructions. Multi-
step action instructions are marked by successive numbers.
Here, you select a function of the interface of SETHC8X.EXE.
Inputs in MS-DOS mode, e.g."hc8xinit" are represented in this style.

Technical Information
HC8X Heat Control
E-8 ©SICK AG · All rights reserved 8010043
Intended Use
Intended Use
The HC8X is an 8-channel heat control. It serves to regulate single and multi-phase heating
circuits.
The control unit is an extension of the modular MODIOS I/O system and can be installed in
an existing I/O module box system.
This control unit has been designed and produced in accordance with a variety of interna-
tional safety standards. There is no potential danger from the control unit when used for its
intended purpose.
To maintain the control unit in a safe condition, it is sufficient to observe some simple, widely
known rules of behavior.
To ensure optimal operation of the control unit, only appropriately trained and skilled per-
sonnel should be allowed to operate the control unit.
Unauthorized Adjustments and Servicing!
Only a SICK service engineer or a similarly trained and authorized person should be per-
mitted to perform service work or adjustments on the control unit.
Please observe the following safety recommendations:
Do not attempt to make internal adjustments or replacements except as directed in this
User's Handbook.
Do not operate the control unit with any covers or parts removed.
To the extent possible, disconnect the control unit from all voltage sources before open-
ing it. If the opened control unit must be operated for further adjustment, maintenance
or repair, this must be done only by a trained person who is aware of the hazard in-
volved and knows how to protect himself with appropriate measures.

Technical Information
HC8X Heat Control
Safety Information
8010043 ©SICK AG · All rights reserved E-9
Safety Information
Electrical hazard!
Dangerous voltage in the control unit.
Even with the power switched OFF, voltage may still be applied to some parts of the control
unit when the control unit is connected to the mains.
For operation, the control unit must always be grounded.
Never disconnect or remove the protective conductors in the control unit or in the sup-
ply line.
Electrical hazard!
To avoid a potential hazard of injury by electric voltage and to prevent the control units
from damage, switch OFF the control unit and disconnect it from the mains at all poles
before performing or modifying any electrical connections.
Verify whether the control unit is voltage-free.
Secure the switched OFF control unit against any unauthorized or unintentional switch-
ing on.
Electrical hazard!
This control unit may be connected to the mains only by authorized/qualified personnel.
Only a SICK service engineer or similarly trained and authorized person should be per-
mitted to service or repair the control unit.
The control unit operates with high voltages. Even with the power switched OFF, high
voltages can be present inside the control unit.
When the control unit is switched on, the electrical connections are live. Opening covers
or removing parts is likely to expose live parts.
Capacitors inside the control unit may still be charged even if the control unit has been
switched off and disconnected from all voltage sources.
Do not attempt to make internal adjustments or replacements except as directed in this
User's Handbook.
Do not operate the control unit with any covers or parts removed.
Disconnect the control unit from all voltage sources before opening it. If the opened
control unit must be operated for further adjustment, maintenance or repair, this must
be done only by a trained person who is aware of the hazard involved and knows how
to protect himself with appropriate measures.

Technical Information
HC8X Heat Control
E-10 ©SICK AG · All rights reserved 8010043
Safety Information
Use only fuses with the required current rating and of the specified type for replace-
ment.
Do not use makeshift fuses or short-circuit the fuse holders.
In case of inadequate grounding or damaged protective conductor (earth/ground ter-
minal), place the control unit out of operation and secure it against any unauthorized or
unintentional operation.
The earth/ground connection can be inadequate if the control unit:
Shows visible damage or has been subjected to prolonged storage under unfavorable
conditions (e.g. humidity).
Has not been correctly handled during transport.
Damaged control unit!
Do not put a damaged control unit into operation.
Whenever it is likely that the control unit is no longer electrically safe for use, place the
control unit out of operation and secure it against any unauthorized or unintentional op-
eration.
The control unit is likely to be electrically unsafe when it:
Shows visible damage
No longer operates correctly
Has been subjected to prolonged storage or operation under unfavorable or 
inadmissible conditions
Has been subjected to inadmissible transport stresses.

Technical Information
HC8X Heat Control
Electronic Components
8010043 ©SICK AG · All rights reserved E-11
Electronic Components
Electrostatic discharges can damage the components. Special precautions are required
when handling electronic components:
Wear a special ESD safety wrist strap and work on a grounded, antistatic surface. If this
is not possible, touch an adjacent grounded conductor (e.g. heating or water pipe) be-
fore handling the components.
Leave the components in their original packaging until you are ready to use them.
Handle electronic components only by their case - strictly avoid touching the contacts.
Keep the components and printed circuit boards away from static-generating material
as e.g. PVC materials, plastic bags, etc.

Technical Information
HC8X Heat Control
E-12 ©SICK AG · All rights reserved 8010043
Environment
Environment
Storage Conditions
You can store the control unit safely under the following conditions:
Ambient temperature —10 Cto + 80 C.
Relative humidity max. 80%, without condensation.
Operating Conditions
The control unit will operate correctly under the following conditions:
Indoors
Ambient temperature + 5 C to + 50 C.
Relative humidity max. 80%, without condensation.
Operation outdoors prohibited
Keep dry.
Protect control unit from shocks and vibrations!
Note When you remove the control unit from storage and before you put it into operation, allow it
to stand for at least one day under the permitted ambient conditions.
Explosion
Explosive atmosphere!
The control unit must not be operated in explosive atmospheres.
Control units designed for use in an explosive atmosphere are available upon request.

Technical Information
HC8X Heat Control
Compliance
8010043 ©SICK AG · All rights reserved E-13
Compliances
The technical design of this control unit complies with the following EC directives and 
EN standards:
EC Directive NSP
EC Directive EMV
Applied EN standards:
EN 61010-1, Safety requirements for electrical equipment for measurement, control
and laboratory use
EN 61326, Electrical equipment for measurement, control and laboratory use - EMC re-
quirements
Electrical protection
Insulation: Class of protection 1 according to EN 61010-1.
Insulation coordination: Measuring category II according to EN61010-1.
Soiling: The control unit operates safely in an environment up to degree of soiling 2 accord-
ing to EN 61010-1 (usual, not conductive soiling and temporary conductivity by occasional
moisture condensation).
Electrical energy: The wiring system to the voltage supply of the system must be installed
and fused according to the relevant regulations.

Chapter 1Technical Information
HC8X Heat Control
1-14 ©SICK AG · All rights reserved 8010043
Product Description
1Product Description
The HC8X is an 8-channel heat control. It serves to regulate single and multi-phase heating
circuits.
The control unit is an extension of the modular MODIOS I/O system and is installed in an
existing I/O module box system.
1.1 Method of Operation of the Control Unit
The HC8X controls the temperatures of up to eight heating circuits in a two-point procedure.
When the control circuits are configured and parameters set accordingly, the actuators of
the heating circuits can be operated in a multi-phase follower mode. All control circuits can
be enabled and disabled independently. The communication to a parent PC measuring sys-
tem is performed via two bidirectional plastic optical fibers in master/slave procedure (for
the control process of the HC8X see Chapter 5.4 Control Process, page 5-34).
1.2 Control Unit Design
The control unit consists of a microprocessor-controlled regulator part with LED indication
and power section for heating circuits with a 3680 VA maximum nominal rating per heating
circuit.
Fig. 1-1: HC8X Overview
X10
X1X9 X2 X3 X4 X5 X6 X7 X8
1.2.1 Special Control Unit Configuration
In the full version, the HC8X heat control is equipped with eight power outputs. When only
some of the control unit outputs are used, the respective terminal blocks of the power out-
puts are blank and the drillings of the thermal overcurrent trips are closed with plastic caps.
Note The HC8X can be retrofitted by the installation of the retrofit kits HC 4A, 8A, 16A with / with-
out load relay (see Chapter 7.1 Retrofitting the HC8X, page 7-36).
Possible Heating Modes
The HC8X can be operated in three heating modes (see Chapter 5.4 Control Process,
page 5-34):
Heating mode "H1" = standard control.
If the temperature to be controlled exceeds the set temperature + limit, a safety relay
which is connected in series with the working relay interrupts the supply voltage of the
heating circuit. When the set temperature hysteresis is reached, the safety relay
closes and the working relay takes over the control switching function.

Technical Information Chapter 1
HC8X Heat Control
Product Description
8010043 ©SICK AG · All rights reserved 1-15
Heating mode "T1" = control with permanent safety temperature switch-off
As standard control "H1", however the safety relay permanently interrupts the voltage
supply of the heating circuit when the set temperature + limit is exceeded. A return to
controlling is possible only by a control reset.
Heating mode "B1" = temperature limiting without control function.
Exceeding the set temperature + limit interrupts the supply voltage of the heating cir-
cuit. A return to monitoring is possible only by a control reset.
The series connection of a controller with "T1" function and a controller with "B1"
function makes possible the temperature control of components in explosion zones.
For safety reasons, the two controllers of a heating circuit may not be located in the
same HC8X heat control.
Note Check the respective heater mode after a control unit change. Readjust as required
(see Chapter 4.5 Configuration and Parameter Setting with SETHC8X.EXE under Win-
dows, page 4-29).
Control unit damage caused by incorrect configuration!
The control unit configuration may be changed only by SICK.
The heat control is supplied configured. Changes to an existing configuration are normally
not required. However, if a configuration needs changing, e.g. to create load symmetry, pro-
ceed according to Chapter 7.2 Configuring the Power Bars, page 7-39.
1.2.2 Schematic Block Diagram
Fig. 1-2: HC8X Block Diagram
DC
115 V/230 V
50 - 60 Hz
Optical serial
interface
TTemperature
sensors
8 x PT100
Microcontroller
Control section
Incoming feeder (X9)
Power section
L1 N PE
HC8X heat control
Socket
with mains filter
Supply line
3P + N + PE
115 V/230 V
50 - 60 Hz
8 x heating circuit
115 V/230 V
50 - 60 Hz
ELR
L3
L2
L1
N
PE
8 x PT100 PE
nI
Neutral voltage
switch (HON)
Safety relay
(HEN)
Therm. delayed
overcurrent trip
Meas. system PC /
other MODIOS
X1 - X8
115 V/230 V
50 - 60 Hz
(X10)

Chapter 1Technical Information
HC8X Heat Control
1-16 ©SICK AG · All rights reserved 8010043
Product Description
Note For the adaptation to the respective heating circuits, the thermally delayed overcurrent
trips installed in the power section have been designed for 4 A, 8 A and 16 A, depending
on the control unit configuration. The use of larger heating circuits is not allowed.
When two- and three-phase heating circuits are connected, the temperature sensors
(PT100) must be assigned to the respective controlling channel (see Chapter 4.5 Con-
figuring the Control Channel as a Follower, page 4-30).
Recommendation For the external fusing of the power electronics supply voltage (X9), install a three-pole
35 A circuit-breaker (see Chapter 10.2 Electrical Data / Temperatures, page 10-45)
near the HC8X or in the MCS 100 E measuring system cabinet.
For the external fusing of the supply voltage of the control electronics (non-heating ap-
paratus connection), install a single-pole 10 A circuit-breaker (see Chapter 10.2 Elec-
trical Data / Temperatures, page 10-45) near the HC8X or in the MCS 100 E measuring
system cabinet.
1.3 HC8X Process Connection
The process connection of the HC8X, e.g. to a MCS 100 E system, is shown in Fig. 3-1.
Fig. 1-3: HC8X Process Connection
HOST
Optical fiber
MCS 100 E
1.4 Signaling
General LEDs
The LEDs (see Fig. 1-4) indicate the set mode and the states of the individual control chan-
nels.
A green, separate LED (LED 25) signals the HC8X operational state "Idle", "Prog" or
"Norm" and the control channel alarm .
Eight green LEDs (LED 1 – LED 8) signal the states of the individual heating circuits.
Eight red LEDs (LED 9 – LED 16) signal the state of the working relays (HON = Heating
ON, see Chapter 5.4 Control Process, page 5-34).
Eight red LEDs (LED 17 – LED 24) signal the state of the safety relays (HEN = Heating
ENable, see Chapter 5.4 Control Process, page 5-34).

Fig. 1-4: Layout of LEDs and Slide Switches on the Printed Circuit Board
6
LED17 LED18 LED19 LED20 LED21 LED22 LED23 LED24
LED9 LED10 LED11 LED12 LED13 LED14 LED15 LED16
LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8
SI1 SI2 SI3
LED25
A
B
1
2
3
4
56
Technical Information Chapter 1
HC8X Heat Control
Product Description
8010043 ©SICK AG · All rights reserved 1-17
1Slide switch = setting of "Idle","Prog" or "Norm" modes and reset 
of HC8X (see Chapter 5.1.1 Setting the HC8X Mode, page 5-32)
2LED 1 – LED 8 = status signaling of the eight heating circuits
3LED 9 – LED 16 = status signaling of the eight working relays
4LED 17 – LED 24 = status signaling of the eight safety relays
5Control fuses
6LED 25 = signaling of HC8X "Idle", "Prog" or "Norm" modes and control channel alarm.

Table 1-1: Significance of General LEDs
LED Signals HC8X in Mode Function
LED 25 (green)
Short blink once per second
Idle EEPROM data invalid
HC8X inactive
Green channel LEDs (1–8) blink at the same rate
LED25 (green)
Short blink twice per second
Prog The serial interface is set to 9600 baud
Control unit parameters can be modified in the processor dialog
LED 25 (green)
Blinks three times per second
Norm At least one control channel is in the alarm state
The respective channel LED blinks at the same rate
LED 25 (green)
Steady light
Norm All EEPROM data are valid
All channels are free from error
LED 1 – LED 8 (green)
Short blink once per second
Idle LED 25 blinks at the same rate
HC8X inactive
LED 1 – LED 8 (green)
Short blink once per second
Norm Associated channel was previously disabled in programming
mode
Control function not available
LED 1 – LED 8 (green)
Short blink twice per second
Prog LED 25 blinks at the same rate
HC8X in programming mode
LED 1 – LED 8 (green)
Short blink three times per second
Norm LED 25 blinks at the same rate
Alarm on respective channel
Error acknowledgment with slide switch or with a software reset
command via the serial interface
LED 1 – LED 8 (green)
Steady light
Norm Correct state of the control of the respective channel
LED 1 – LED 8 (green)
Long blink once per second
Norm The respective control channel was set to follower mode in the
programming mode
The heating circuits follow the control function of the previous
channel
LED 9 – LED 16 (red)
Steady light
Norm Working relay of channels 1–8 is excited
LED 17 – LED 24 (red)
Steady light
Norm Safety relay of channels 1–8 is excited
Chapter 1Technical Information
HC8X Heat Control
1-18 ©SICK AG · All rights reserved 8010043
Product Description

Technical Information Chapter 2
HC8X Heat Control
Installation/Removal
8010043 ©SICK AG · All rights reserved 2-19
2Installation/Removal
2.1 Selecting the Installation Location
Short-circuit caused by moisture or dust!
Observe the degree of protection (IP 20) when selecting the installation location.
Do not install the control unit in a humid or dusty environment.
Distance between HC8X and Measuring System PC
The length of the optical fiber between the HC8X or an I/O module box and the measuring
system PC may not exceed 60 m.
2.2 Installing the HC8X
Control unit damage by overheating!
Install the HC8X horizontally, if possible.
If required, install the HC8X vertically so that the ventilator on the side points downward
Ensure adequate heat dissipation.
Install the HC8X so that the internal control unit ventilator can draw in cool air unhin-
dered.
1. Position the HC8X on the installation plate or a control unit carrier; observe a minimum
distance of 5 cm between the heat sink and adjacent control units.
2. Ensure a firm base and good attachment of the control unit.
564
71
109
Ventilator Heat sink
Fig. 2-1: HC8X Attachment

Chapter 2Technical Information
HC8X Heat Control
2-20 ©SICK AG · All rights reserved 8010043
Installation/Removal
2.3 Removing the HC8X
1. Shut down the measuring system.
2. Switch off the supply voltage of the control electronics and pull the plug from the mains
socket.
3. Switch off the supply voltage of the power electronics and secure against switching on
again.
4. Pull all plugs of the external temperature sensors from terminal strip X10.
5. Unscrew two cross-slotted screws from the case cover, pull off the plug connection of
the grounding line and remove the case cover.
6. Check whether the supply line on terminal strip X9 is free from voltage. When this is the
case, disconnect the wires.
7. Pull all plugs from terminal strips X1 to X8.
8. Loosen the four attachment screws on the case base plate of the HC8X by a few turns
and lift the HC8X from the attachment.
9. Change individual electrical or mechanical assemblies only after contacting SICK. A fur-
ther disassembly of the HC8X heat control is not intended.
For the environmentally compatible disposal during the final shut-down, proceed according
to Chapter 9 Disposal, page 9-43.