HC500 Heater Controller Diagnostic HETRONIK GmbH Heisinger Str. 12 D-87437 Kempten / Germany phone: +49 / (0)831-56 58 59-34 fax: +49 / (0)831-56 58 59-39 e-mail: contact@hetronik.de www.heatcontrol.com HC500-diagnostic_en.doc / September 05, 2016
Table of contents 1 Table of contents 1 Table of contents 2 2 LED diagnostic 3 2.1 CPU-unit (CU) 3 2.1.1 With PROFIBUS-DP 4 2.2 Output-card () 5 2.3 Output-module-master (OMM) 6 2.4 Output-module (OM) 7 2.5 Output-unit (OU) 8 2.6 Output-unit-ampmeter (OUI) 9 2.7 Voltage-unit (VU) 10 2.8 Temperature-unit 11 2.8.1 (TU) 11 2.8.2 (TU-V2) 12 3 Diagnostic with WINDOWS software 13 page 2/15 HC500 Diagnostic
LED diagnostic - CPU-unit (CU) 2 LED diagnostic 2.1 CPU-unit (CU) H3 H4 H5 H6 H7 H8 H9 0 1 2 3 4 5 6 H3 H4 H5 H6 H7 H8 S3 S1 VU TU --- ON normal ON softsart volt. comp. save param. H9 0 1 2 3 4 5 6 power supply power circles temperat. master com. HC-BUS HC-NET/HC-COM PROFIBUS-DP HC500-DIAG2 CU no. (1 CU only = "0") + S2 quantity S4 1 2 3 4 off = on = HC-standard KISS HC-COMascii HC-COMhex save TUQ & TALP save all HC-parameters --- --- output-cards ()* all present CPU (CU) 24 Vdc supply voltage min. 1 or voltage-unit (VU) S1 + S2 wrong VU present & ok VU not present VU not present but power voltage fluctuation compensation = ON [error] H3 temperature-units (TU) all TU present & ok no TU setup min. 1 TU [min. 1 TU with failure] H4 --- --- --- --- H5 power-outputs heating ON with normalstart H6 heating ON with softstart(light) H7 power voltage fluctuation compensation heating OFF [automatic heating OFF because of communication problem] ON heating OFF --- H8 --- --- --- --- * = output-cards has same meaning as OM = output-modules and OU = output-units HC500 Diagnostic page 3/15
LED diagnostic - CPU-unit (CU) continue H9 power voltage red --- power voltage of all s ok 0 power circles red error in one or more power circles 1 monitoring of HCelectronic red min. 1 > 60 C temperature 2* communication with master 3 HC-BUS yellow all, VU, TU present min. 1 with power voltage problem [emergency mode power voltage] ok --- normal emergency mode electronic temperature red --- disturbed or faulty no, VU, TU found min. 1, VU, TU or wrong address 4 HC-NET / yellow data exchange no data exchange data exchange HC-COM 5 PROFIBUS-DP yellow data exchange no data exchange --- 6 HC-DIAG yellow HC-DIAG2 active HC-DIAG2 not active HC-DIAG2 is master [simulation mode] * firmware 2.0 and higher 2.1.1 With PROFIBUS-DP 7 DP yellow PROFIBUS-DP connected PROFIBUS-DP not connected --- page 4/15 HC500 Diagnostic
LED diagnostic - Output-card () 2.2 Output-card () LED (red) on blinking 0.5 s on / 0.5 s off fast blinking 0.1 s on / 0.1 s off off meaning min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted triac power voltage problem "emergency mode - power voltage" is active all power circles ok LED (yellow) on long on blinking 0.9s on / 0.1 s off blinking 0.5 s on / 0.5 s off fast blinking 0.1 s on / 0.1 s off off meaning heating ON ready for heating ON electronic temperature > 60 C HC-BUS Problem 24 Vdc on HC-BUS or is defective Old s with one LED only: LED (yellow) on long on blinking 0.9s on / 0.1 s off short on blinking 0.1s on / 0.9 s off blinking 0.5 s on / 0.5 s off fast blinking 0.1 s on / 0.1 s off off meaning heating ON ready for heating ON power voltage problem min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted triac "emergency mode - power voltage" is active 24 Vdc on HC-BUS or is defective HC500 Diagnostic page 5/15
LED diagnostic - Output-module-master (OMM) 2.3 Output-module-master (OMM) H3 H4 H5 H6 OMM power voltage ok 24 Vdc on X2 H4 HC-BUS yellow ok 24 Vdc on HC-BUS communication problem OM-BUS1 yellow all OM found no OM (S1 = "0") min. 1 OM or S1 = wrong H3 power voltage and power circles of OM's at OM-BUS1 red min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted triac ok min. 1 OM power voltage problem or [min 1 OM emergency mode power voltage] H5 OM-BUS2 yellow all OM found no OM (S2 = "0") min. 1 OM or S2 = wrong H6 power voltage and power circles of OM's at OM-BUS2 red min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted triac ok min. 1 OM power voltage problem or [min 1 OM emergency mode power voltage] page 6/15 HC500 Diagnostic
LED diagnostic - Output-module (OM) 2.4 Output-module (OM) H3 H4 H5 power circles red min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted triac ok power voltage problem [emergency mode power voltage] LED (yellow) on blinking 0.5 s on / 0.5 s off fast blinking 0.1 s on / 0.1 s off short off blinking 0.9s on / 0.1 s off off meaning heating ON HC-BUS problem electronic temperature > 60 C ready for heating ON 24 Vdc on HC-BUS or OM is defective H4 output 1 H5 output 2 100% output 1 99% output 0 % (no) output H6 output 3 HC500 Diagnostic page 7/15
LED diagnostic - Output-unit (OU) 2.5 Output-unit (OU) H4 3 6 H3 H4 LED on present ok 24Vdc at X2 HC-BUS / OUI-BUS / OUI {heat ON} SSR control outputs power cirles {voltage at X3} H5...6 --- LED off no 24 Vdc short circuit all ok --- failure ok LED blinking com error; no OUI {ready} [] SSR ctr outputs {ESP} 100 % 0 % (off) 1... 99 % {failure} {0.9s on / 0.1 s off] [0.5 s on / 0.5 s off] (0.1 s on / 0.1 s off) 24 Vdc at X2 present --- HC-BUS, OUI- BUS and OUI yellow ok 24 Vdc on HC-BUS communication problem or OUI {ready for heating ON} H3 SSR control red min. 1 short circuit all ok --- outputs H4 power circles red min. 1 power circle with min. 1 failure = fuse, heater or cable broken or shorted ok SSR X3) H5 SSR control 6 outputs [power voltage at X3 ] (not 50 or 60 Hz power voltage at working at 100 % off working at 1 99% [fuse, heater or cable broken or shorted SSR] page 8/15 HC500 Diagnostic
LED diagnostic - Output-unit-ampmeter (OUI) 2.6 Output-unit-ampmeter (OUI) amp measurement active not active --- OUI-BUS yellow ok not present error HC500 Diagnostic page 9/15
LED diagnostic - Voltage-unit (VU) 2.7 Voltage-unit (VU) phase voltage L1, L3, L3 red min. 1 phase absent or non 3 different ok all phases not present phases HC-BUS yellow ok 24 Vdc on HC-BUS communication problem page 10/15 HC500 Diagnostic
LED diagnostic - Temperature-unit 2.8 Temperature-unit 2.8.1 (TU) H3 H4 H5 H6 H7 H8 H9 0 channel 1 and channel 2 and channel enabled and ok channel not enabled [ defective or or input defective] H3 channel 3 and H4 channel 4 and H6 channel 5 and H7 channel 6 and H8 channel 7 and H9 channel 8 and H5 HC-BUS yellow ok 24 Vdc on HC-BUS communication problem 0 temperature controller yellow min. 1 temperature controller active no temperature controller active auto tuning active HC500 Diagnostic page 11/15
LED diagnostic - Temperature-unit 2.8.2 (TU-V2) HC-BUS yellow ok 24 Vdc on HC-BUS communication problem temperature yellow min. 1 temperature no temperature auto tuning active controller controller active controller active H3 --- red --- --- --- H4 channels 1...8 red of all enabled channels, min. 1 is defective or and/or min. 1 input is defective inputs and s of all active channels are ok --- H5 H6 H7 H8 channel 1 and channel 2 and channel 3 and channel 4 and channel enabled and ok channel enabled and ok [ defective or or input defective] H9 channel 5 and 0 channel 6 and 1 channel 7 and 2 channel 8 and channel enabled and ok channel enabled and ok [ defective or or input defective] page 12/15 HC500 Diagnostic
Diagnostic with WINDOWS software 3 Diagnostic with WINDOWS software For a more detailed diagnostic of the HC500 system, we e-mail the freeware WINDOWS diagnostic software HC-DIAG2 (sucessor of HC500-DIAG2) for CUs with firmware version 2.00 or higher or HC500 Diagnostic page 13/15
Diagnostic with WINDOWS software HC500-DIAG for CUs with firmware version 1.15 to 1.19. page 14/15 HC500 Diagnostic
CU VU TU TU OMM OMM OU OU OU OU SC Diagnostic with WINDOWS software RK-8 RK-4 OUI OUI OUI OUI USB (older CU versions = RS232) OM HC500- DIAG(2) OM OM OM-FU HC500 Diagnostic page 15/15