Controller for Electric Heaters

The energy and electricity infrastructure in all countries working towards the green transition is undergoing significant change.
This transformation is driving a growing need for more intelligent power consumption that can rapidly adapt to current frequency and energy availability.

Electric heating elements hold vast potential for flexible adaptation

Electric heating elements collectively represent a major potential for flexible energy consumption regulation. Historically, their regulation has been based on relatively simple principles, such as thermostats and pulsed control, adjusting energy consumption based on the heating material’s needs.

The future demands intelligent control

This approach will no longer be sufficient. There is already a need to balance the load on the power grid—a need that will only increase in the future. Since electric heating elements offer substantial regulation potential, we are actively developing intelligent electronic controllers for heating elements to meet this demand.

Technical setup and installation

The control system is based on well-known power ratings and mounting methods, such as direct mounting on the heating element. When mounted directly, the maximum load is 3x16A. Alternatively, a control box can be installed next to the heating element in a machine or on a wall, where the maximum load increases to 3x25A.

Handling grid instability

The control system detects frequency drops and surges in the power grid and automatically adjusts power consumption to prevent flicker and power outages. This regulation happens so quickly that the controller can switch off the heating element the moment a cloud covers the solar panels, causing a sudden drop in energy production—essentially shifting to another energy source.

To ensure faster and more precise regulation, the system is equipped with hybrid relays. This allows the controller to react instantly to fluctuations in energy supply. Hybrid relays also enable a soft start for the heating element, preventing sudden high current draw when the relay activates, which extends relay lifespan.

Control options and configuration

The system can regulate either as on/off or stepless 0-100%, depending on the selected model. Regulation is based on 0-10V signals, ModBus, potentiometers, or PT1000 temperature sensors.

Additionally, it is equipped with LAN RJ45, WiFi, and Bluetooth modules. Internet access via LAN or WiFi allows integration with LS SmartConnect Center, where systems can be grouped, managed, and monitored remotely.

The Bluetooth connection is essential for linking with the LS Config App, where setup, operation, and service can be managed via smartphone or tablet. The LS Config App also includes helpful tools to reduce the need for on-site technician visits, saving time and travel costs for specialized installers and experts.

Essential customization and optional optimizations in the LS Config App

In the LS Config App, the user must define the extent to which the heating element may adapt to grid stability. For example, users can set time intervals for when the controller is allowed to adjust to the power grid and when energy storage can occur—such as increasing the temperature in a water tank.

To optimize operating costs, the LS Config App’s adaptive energy management tool enables automatic energy consumption regulation based on electricity prices and weather forecasts.

Want to know more?

We welcome a dialogue, so please contact us with your challenges and requirements for a heating element controller, and let’s find the right solution together.