Test stand for CO2 accumulator electric heaters

M a c i e j O s t r ę g a , P i o t r D z i u r d z i a 2 2 . 0 4 . 2 0 1 5

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• Test stand is working since 15 of March…• Watlow and DIMECA Heaters still alive• On 21.04 has been make swagelok connection on the

Watlow heater to create the same conditions like in CO2 accumulator. The result should be soon.

Status

Tested heaters

Manufactor Manufactor no Details Nominal voltage [V]

Nominal power [W]

WATLOW FIREROD 1348K Standard epoxy insulation. Silicon wires. 240 1000

DIMECA 14/1219090° bent, 55 mm metal tube

insulation and 1100 mm flex hose additional insulation for silicon

wires.230 1000

WATLOW

DIMECA

Tested heaters

Heatername Manufactor Calculated power

at 230VInsulation resistance L-PE

at 1051VInsulation resistance N-PE

at 1051V

IBL_004 DIMECA 916.8 + 11 GΩ + 11 GΩ

IBL_009 DIMECA 951.4 + 11 GΩ + 11 GΩ

CMS_010 WATLOW 961.8 403 MΩ 403 MΩ

Measurements before the test

Test cycle

1. Heating ON with high temp. setpoint 15 °C2. Heating ON with low temp. setpoint -40 °C3. Heating OFF with low temp. setpoint -40 °C [-55 °C]

Results and conclusion

1. All heaters are working fine2. No epoxy damage observed after several heating-cooling cycles3. Epoxy cracking can be caused by the swagelok fittings – under the test4. DIMECA heaters has a big (huge) time delay with the response on power –

interlocked heater at 120°C reached almost 300°C – no possibility to use it as an accumulator heaters!

Results and conclusion

Heatername Manufactor Calculated power

at 230VInsulation resistance L-PE

at 1051VInsulation resistance N-PE

at 1051V

IBL_004 DIMECA 916.8 + 11 GΩ + 11 GΩ

IBL_009 DIMECA 951.4 + 11 GΩ + 11 GΩ

CMS_010 WATLOW 961.8 2.8 GΩ (cold)~200 MΩ (warm)

2.8 GΩ (cold)~200 MΩ (warm)

Measurements after the test

Heatername Manufactor Calculated power

at 230VInsulation resistance L-PE

at 1051VInsulation resistance N-PE

at 1051V

IBL_004 DIMECA 916.8 + 11 GΩ + 11 GΩ

IBL_009 DIMECA 951.4 + 11 GΩ + 11 GΩ

CMS_010 WATLOW 961.8 403 MΩ 403 MΩ

Measurements before the test

Other solutions

Standard WATLOW heater with additional silicone insulation

Other solutionsVULCANIC heaters

TODO

1. Continue the test of the heater with Swagelok connection2. Additional studies for the floating insulation resistance problem3. New tests with the new heaters - WATLOW with additional insulation +

Vulcanic (?)

Backup slides

Test stand

Test stand

Designed by Tomasz Kucharski

Test procedure

• electrical measurements• heating with cooling (setpoint high)• no heating with cooling (setpoint -40 °C)

more details:(DFS) …/PROJECTS/ Accumulator_Heaters_Teststand/DOCUMENTS/

Test stand for CO2 accumulator electric heater.docxAccumulator electric heater - DATA.xlsx

Electrical measurements• resistance of the heater• insulation resistance• earth leakage current

more details:(DFS) …/PROJECTS/ Accumulator_Heaters_Teststand/DOCUMENTS/

Test stand for CO2 accumulator electric heater.docxAccumulator electric heater - DATA.xlsx

Calculated EH resistance [Ω]

Measured EH resistance [Ω]

Insulation resistance [MΩ]

Comments

Calculated earth leakage current at 230V Measured earth leakage currentVoltage during the measurements [V]

Calculated insulation resistance [MΩ]

Test voltage >> 50V 100V 250V 500V 1000V [mA] [uA] [mA] [uA]

52.9 52.8

L/PE - - - - 11000 over the measurement range ( >11 GΩ) 2.09091E-05 0.021 - 0.021 230.0 10952.381

N/PE - - - - 11000 over the measurement range ( >11 GΩ) 2.09091E-05 0.021 30.000 - 230.0 0.008