Energy Regulators

Energy Regulators

Energy Regulator

Description of Energy Regulators

The Energy Regulators affects its control by periodically switching the power on and off, the ratio of the on time to the total time determining the average power input. As compared with a variable resistance, the energy regulators are in general cheaper, far less bulky and applicable to any load up to its rated capacity. Moreover, the control is affected without the loss of energy associated with resistance control is variable continuously from no load to full load and is substantially independent of mains voltage fluctuations up to about 20%.

The energy regulators mainly consists of a heated bimetal and a snap-action switch (spring contact). Fig. 1 below will make the mode of operation clear.

• Is a bimetal strip holder carrying a cam follower whose function is to compensate for variations of ambient temperature
• Is a bimetal strip carrying a heater winding
• Is a snap-action switch operating the contact
• Is a knife edge about which the bimetal assembly can pivot
• Is a means of adjustment

Normally the contact D is closed so that current flows through the heater winding on the bimetal and through the load. The bimetal warms and, in bending, opens the switch C, interrupting the current both to the heater winding and to the load.

The bimetal then cools and the cycle is repeated. The ratio of the time during which the contacts are made, to the total time of the cycle, determines the average input.

This ratio is controlled by the adjusting cam F. Clearly if the cam is set so that the contacts remain closed with the maximum deflection of the bimetal, the power will be permanently on; if the cam is turned until the contact D is open with the bimetal cold, the power will be permanently off. Between these two limits the input is continuously adjustable.

Since the same voltage is applied to the energy regulators as is applied to the load, any variation will affect the two similarly, so that the average input is independent of applied voltage over a wide range.

Technical Specifications of Energy Regulators

• Long duty cycle and short intervals between heating = greater average output, e.g. for heating up
• Short duty cycle and long intervals between heating = smaller average output, e.g. for simmering
• The output of the load can be set to between 6% to 85% of the rated output. Select highest setting for full nominal rating (100%).
• Infinitely variable control of the power supply

Energy regulators control is applied with saving and convenience to an extremely wide range of process heating apparatus replacing a resistance or potentiometer.

• In apparatus where it is inconvenient or impossible to fit any type of thermostat, e.g. hot plates, injection moulding nozzles, moulding patterns, etc.
• For small, high temperature ovens and furnaces where the costs of temperature control would be excessive.
• For any heating process where the temperature is a function of power input only.
• To control the rate of change of temperature in a furnace with a view to reducing the differential or temperature spread permitted by conventional temperature controllers.
• For controlling the input to a furnace so as to obtain rapid heating without undue overrun at the operating temperature.
• To control the average output of a motor driving, for instance, a conveyor or pump where there id no objection to the motor being periodically started and stopped, e.g. a pump filling a tank, a motor driving an automatic stoker or a belt travelling through a furnace.

Infinite Control Switch / Heat Switch

Description of Infinite Control Switch / Heat Switch

The infinite control switch / Heat switch gives infinite control / Heat switch for non-inductive loads up to 15 Amps on 120 or 240 V-AC (cannot be used with an external contactor). It can be turned either to left or right to adjust proper heat from 0-100% wattage with infinite control switch over the first 50% of total wattage. Energized continuously in HI position, at other settings it delivers selected input level under control of a simple bimetal timer. Only 3 mounting holes are necessary to install the INFINITE CONTROL / HEAT SWITCH in customer supplied box or panel. It is designed for use at ambient temperatures up to 85°C.

The model INF turns clockwise or counterclockwise.. A double-line disconnect is provided when the control is in the "Off" position. The permanent magnet provides snap action of contacts. Clean makes and breaks ensure long life of the fine silver contacts. The switch control is ambient compensated. It is designed for operation where ambient temperature does not exceed 85°C. The control contains a bimetal, which regulates the running cycles.

This bimetal has a resistance wire wrapped around it, which is connected in parallel with the heating unit being controlled and cycles in unison with the heating element. When the switch is turned to "ON" position, the follower moves out and allows the contacts to close. This completes a circuit through a heating unit being controlled, and also to the resistance wire wrapped around the bimetal. At this time the steel armature is under the influence of the magnetic pull of magnet. As the resistance wire heats the bimetal, the bimetal flexes and forces are built up in it. When the force built up is equal to the magnetic pull of the magnet, the contacts open with a snap action and the steel armature will be pulled away from the magnetic field. This opens the contacts, which will cut off the power of the heating unit being controlled and will also disconnect the power to the bimetal-Resistance wire. As the bimetal cools, it will then flex in the opposite direction and the contacts will start moving closer together. At a certain point the magnetic pull will close with a snap action. This then will permit current to flow throughout the unit once again as the circuit is complete. A second bimetal is employed as an ambient temperature compensator to neutralize the effect of the surrounding temperatures on the control bimetal. These controls are designed to operate in locations where the maximum ambient temperature does not exceed approximately 85°C. The infinite control switch can control any resistive load up to 15 amps. It is possible to obtain a range of inputs to the element and/or load from approximately 5% at low- 100% at high, and infinite settings in between.

• Simplicity of design with no cams or levers to adjust, and no motor to burn out
• Automatic compensation for line voltage fluctuations up to ± 15%
• Bimetal acts at settings less than HI to limit electrical input and depress temperature
• Mechanical Bi-Metal Operation
• Knob Setting 0 - 100% Output
• Double Pole, Single Throw
• (DPST) Snap-Action
• Positive Break
• 120 or 240 V(Ac) depending on model
• 1,800 & 3,600 Watts
• Cannot be used with a contactor

Applications of Infinite Control Switch / Heat Switch

• Annealing
• Melting Pots
• Industrial Cooking
• Dies
• Platens
• Comfort heating
• Electric Furnaces
• Molding
• Industrial hot plates
• Laboratory Ovens

L1 and L2 represent line connections at the incoming source.
H1 and H2 equal load connections that are connected to the load.
"P" is for pilot light attachment.
Maximum Thread Torque 12 in/lbs for palnut mounting.

Annealing, Melting Pots, Industrial cooking, Dies, Platens, Comfort heating, Electric furnaces, Molding, Industrial hot plates, Laboratory ovens.

Fire Hazards, these devices function as energy controls only. Because they do not fail-safe, an approved temperature or pressure safety control must be used for safe operation.