TECHNOLOGY IN ACTION
V ADVERTORIALS Best practice for high limit safety sensors
Electrical heating systems have several safety fea- tures built in to prevent dangerous situations. High- limit sensors, or safety sensors, are one of the most important. Not only do they protect people, they help keep manufacturing lines running by limiting damage to equipment and product. In this article, Jeremy Ohse at industrial heater,
temperature sensor, and controller manufacturer, Watlow, explores best practice and considerations for high-limit safety sensors.
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Thermal loops consist of a heater, temperature sensor, and heater controller. The controller has a temperature setpoint, receives a signal from the temperature sensor, and modulates power to the heater to maintain the temperature set- point.
If there is a failure in the primary thermal control loop, the redundant safety sensor can tell the controller to reduce power to the heater or shut down the entire system. The most common failures are physically damaged sensors, worn out components, and pinched wires.
In an application away from industry, a hot tub uses a high-limit sensor to pre- vent the water from getting too hot. If the primary control loop fails, the heater will continue to heat the water. When the water temperature reaches a certain level, usually between 110 and 120 °F, the high-limit sensor disables the heater to keep the water at a safe, enjoyable temperature.
To provide additional safety, when the high-limit sensor trips the system, users are “latched out” until the system is inspected and reset by an operator, system designer, or manufacturing engineer. Once the system is repaired and reset, it will operate normally again. In the hot tub example, the high-limit sensor will likely disable the pump in addition to the heater.
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JUNE 2024 | ELECTRONICS FOR ENGINEERS 49
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