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DigiTrace® 920 Series Heat Trace Controller

1. LE IK ep 0 Ka Ke Ce cod Kee Ke a D 9 OO OI xls x SC sx x OI CON ol Ur ol oo Oo Capa o DDODODODODDODODDODDDAO B 4 Eight Point Assembly 10160 035 8 Point FRP 1 pole 30 A SSR assembly Model 920 E10FWQ1 SIS308 SS3108 lt 30 11 gt lt 12 95 gt E 24 11 gt A A 30 51 31 32 Y Y 21 86 gt Mounting holes 0 375 diameter 4 places O O O cook pong Dm 1111111111 I I HE T ola E h
2. Mounting holes 0 3 diameter 4 places DigiTrace 920 Series 099999990 63 B 2 Dual Point Assemblies 10160 120 and 10160 121 2 Point FRP 1 or 2 pole 30 A SSR assembly 1 Pole Model 920 E4FWL SIS302 S53102 2 Pole Model 920 E4FWL SIS302 SS3202 lt 8 31 gt lt 18 00 gt lt DN D E r A 08 lt 10 00 gt Mounting holes 0 3 diameter 4 places bd pd Ah VIT TT TA el oog lie O Uy paa BO hh d 8 WaT III aca S aca o 64 B 3 Four Point Assembly 10160 125 4 Point FRP 1 pole 30 A SSR assembly Model 920 E6FWL SIS304 553104 x 8 31 2 17 27 16 13 Mounting holes 0 3 diameter 4 places
3. GFI Trip Enable GFI Trip 15 mA Lo Volt Enable Lo Volt 90 V Lo Volt Filter 0 sec Hi Volt Disable Hi Volt n a 270 V Hi Volt Filter n a 0 sec Lo Resist Disable Lo Resist n a 50 Lo Resist Filter n a 0 sec Hi Resist Disable Hi Resist n a 50 Hi Resist Filter n a 0 sec Nominal Resist n a 6 00 Q Overcurrent Trip Enable Switch Fail Enable HTC Reset Disable C B Limiting Disable Power Limiting Disable Switch Limiting Disable Contactor Count n a Enable Countactor Count n a 200 000 EEROM Data Fail Enable 81 82 Point Setup Sub Menu Parameter Factory User Tag TAG factory ID Switch Control Mode Proportional Prop Band 4 F 2 C Deadband n a 5 F 3 C Cycle Time n a 10 min Switch Rating 30 0 A Circuit Breaker 30 0 A Max Power 7200 W 3 Ph Pwr Calc No TS Fail Mode Off TS CTL Mode TS1 Fail Off TS 1 Type 100 Q Plat TS 1 Lead Resist n a 0 Q TS 1 Hi Limit Disable TS 2 Type 100 2 Plat TS 2 Lead Resist n a 0 Q TS2 Hi Limit Disable Volt Source Pt A or Pt B Fixed Volt n a 120V Volt Turns Ratio 1 00 to 1 Current Turns Ratio 1 00 to 1 Autocycle Enable Autocycle Interval 8 Autocycle Units Hours Override Source Remote Load Shedding Disable Common Setup Sub Menu Parameter Factory User Temperature Units SE Version V3 2x xx n
4. Ohms F c Ohms F C Ohms F E 69 8 100 73 133 4 155 68 218 2 410 210 71 95 70 134 8 160 71 220 1 415 212 72 3 90 67 136 3 165 73 222 0 420 215 73 1 85 65 137 8 170 76 223 9 425 218 74 3 80 62 139 3 175 79 225 8 430 221 75 5 75 59 140 8 180 82 227 7 435 223 76 7 70 56 142 3 185 85 229 6 440 226 78 0 65 53 143 8 190 87 231 5 445 229 78 8 60 51 145 3 195 90 233 5 450 232 80 0 55 48 146 8 200 93 235 4 455 235 81 2 50 45 148 4 205 96 237 4 460 237 82 2 45 42 149 9 210 98 239 3 465 240 82 9 40 40 151 5 215 101 241 3 470 243 84 2 35 37 153 0 220 104 243 3 475 246 85 7 30 34 154 6 225 107 245 3 480 248 86 9 25 31 156 2 230 110 247 2 485 251 88 1 20 28 157 7 235 112 249 3 490 254 88 9 15 26 159 3 240 115 251 2 495 257 90 1 10 23 160 9 245 118 253 3 500 260 91 4 5 20 162 5 250 121 255 2 505 262 92 2 0 17 164 2 255 123 257 3 510 265 93 4 5 15 165 8 260 126 259 3 515 268 94 5 10 12 167 4 265 129 261 4 520 271 95 8 15 9 169 0 270 132 263 4 525 273 97 1 20 6 170 7 275 135 265 5 530 276 98 3 25 3 172 3 280 137 267 6 535 279 99 5 30 1 174 0 285 140 269 6 540 282 100 8 35 1 157 7 290 143 271 7 545 285 102 0 40 4 177 4 295 146 273 8 550 287 103 3 45 T 179 1 300 148 275 9 555 290 104 5 50 10 180 8 305 515 278 0 560 293 105 9 55 12 182 5 310 154 280 1 565 296 107 2 60 15 184 2 315 157 282 3 570 298 108 5 65 18 185 9 320 160 284 4 575 301 109 8 70 21 187 6 325 162 286 5 580 304 1111 75 23 189
5. FI 66 B 5 Twenty Point Assembly 10160 045 20 Point FRP 1 pole 30 A SSR assembly Model 920 E14FWQ1 SIS320 SS3120 lt 12 95 gt 38 48 40 35 31 32 Y 30 24 gt O o o o Paa o EESTI y pe asta aa ela Leia borg bira Vase gal PG En H ores lU ma o o o o Se o N o Eh EEH EEH FE E E o o Mounting holes 0 375 diameter 4 places 67 Appendix C Wiring Diagrams
6. C 5 3 TEMPBUS AND INHIBIT MASTER SLAVE CONNECTIONS 6 Terminal board Terminal board Ext contact 4 n Bi gt y 20 Ext contact Output 5 p gt 21 Input Ext contact 204 lt 2 Input A1 aed Ambient sensing master 920 controller Up to 25 slave 920 controllers 50 points may be tied to one master 920 controller Note that the master and slave controllers must be installed within the same enclosure Terminal board amp gt 20 Ext contact amp 4 21 Input Terminal board l A pene nea 20 Ext contact gt 21 Input 5VDC to 24 00 nominal 10ma max Slave 920 controller 1 Slave 920 controller 2 pA Slave 920 controller 25 73 Appendix D HTC Load Shedding Sequence 74 Load Normal control shedding mode command received HTC load shed enabled All other contact inputs active 1 HTC holds its output OFF for 30 seconds Is communications active 2 Control at low temp alarm setpoint Has HTC power been reset All matching HTCs set their outputs to OFF HTC display indicates load shedding mode 4 HTC temp at low temp alarm SP 3 Fail safe mode enabled 1 If an HTC is associated with more than one contact input
7. 920 Series SSR Output Modules Operating Temperature 40 F to 104 F 40 C to 40 C Switch Rating e 30 A resistive continuous Y 277Vac max standard 600 Vac max optional 1 PH 50 60 Hz 80 A 1 sec in rush 625 A 1 cycle in rush 60 A resistive continuous 600 Vac max 1 PH 50 60 Hz 120 A 1 sec in rush 1000 A 1 cycle in rush Input Drive Requirement 4 32 Vdc 1500 Q nominal input resistance Environment 920 Series Contactor Ratings Type 4X IP66 Operating Temperature 40 F to 104 F 40 C to 40 C Contact Rating 30 A resistive continuous 600 Vac max standard 60 A maximum opt 50 60Hz 3 pole Coil Rating 120 or 208 240 or 277 Vac 50 60 Hz 109 VA in rush 10 VA sealed 920 Series Operator Console Operating Temperature 40 F to 104 F 40 C to 60 C Power Requirement 9 Vdc nominal 500 ma maximum Appendix B Typical Enclosure Dimensions The following drawings provide the user with enclosure size and mounting dimensions for the stock enclosure assemblies Please contact your local Tyco Thermal Controls representative for information regarding other available sizes and configurations B 1 Single Point Assemblies 10160 003 and 10160 009 1 Point FRP 1 or 2 pole 30 A SSR assembly 1 Pole Model 920 E2FWL SIS301 SS3101 2 Pole Model 920 E2FWL SIS301 SS3201 lt 6 25 gt lt 33 68
8. 1 C to 50 C above setpoint Temperature inputs 2 RTD inputs 3 wire 1009 Platinum DIN 43760 a 0 0038502 Q C or 2 3 wire 1002 Ni Fe open shorted sensor detection protection lead resistance compensated 0 to 20Q per lead Temperature measurement range 76 F to 1058 F 60 C to 570 C accuracy 0 5 of span 1LSD Voltage measurement range 50 to 295 Vac with voltage turns ratio 1 1 accuracy 1 of span 2LSD repeatability 1 5 of span Current measurement range 0 3 to 100 A with current turns ratio 1 1 resolution 0 1 A 0 3 to 11 A range 0 3 A 11 to 40 A range 0 7 A 40 to 100 A range accuracy 2 5 of reading resolution repeatability 3 of reading resolution GF current measurement range 20 to 250 ma accuracy 2 5 of span 2 LSD at nominal load repeatability 4 of span Alarm relay output Dry contact 48 Vac dc 500 ma 10 VA switching maximum 920 Series SSR Switch Interface Module Operating temperature 40 F to 140 F 40 C to 60 C Power requirements 100 to 277 Vac nominal 1 PH 60 Hz 3 Hz or 50 Hz 2 Hz 100 ma maximum Output power 9 Vdc nominal 650 ma maximum SSR drive Current sense range 9 Vdc nominal 75 ma maximum 1000 1 0 3 to 60 A 50 60 Hz 1 PH GF current sense range 1000 1 20 to 250 ma 50 60 Hz 1 or 3 PH Wiring terminals 28 14 AWG strip length 0 33 61 62
9. 5 3 Load Shedding Control Mode eee eee eee eee eens 52 5 4 TEMPBUS Control Mode 53 Section 6 Troubleshooting ccc eee eee ees 55 6 1 Operator Check 55 6 2 Common Problem AreaS 000 c cece cece cece eee em 55 6 3 Common Alarms What to look for 58 Section 7 Maintenance 60 7 1 Operator Maintenance 60 2 Replac ableP TEE 60 Appendix A Specifications llle 61 Appendix B Typical Enclosure Dimensions 00 63 B 1 Single Point Assemblies 10160 003 and 10160 009 000 63 B 2 Dual Point Assemblies 10160 120 and 10160 121 0000 64 B 3 Four Point Assembly 2101p0 1728 65 B 4 Eight Point Assembly 10160 035 000 66 B 5 Twenty Point Assembly 10160 045 nr 67 Appendix C Wiring Diagrams 0 0 ccc eee 68 Cal td dots das a bd ra 68 C 2 Power Wiring mH 70 C 3 Communication Wiring Ie 71 C 4 Alarm Output Wiring eee eee 71 C 5 External Input Output Port Wiring esperi 0 cece eee 73 Appendix D HTC Load Shedding Sequence 0 00 eee eens 74 Appendix E 100 Q Platinum RTD Table 15 Appendix F 100 Q Nickel Iron RTD Table 76 Appendix G Factory Default Configuration Sheet TI G 1 Configuration
10. 0 to 12 seconds Procedure Adjust the HIGH CURRENT ALARM FILTER time to the desired value Note that the HIGH CURRENT ALARM must be enabled in order to adjust the HIGH CURRENT ALARM FILTER time Notes e H an alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e f the user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 5 HIGH GROUND FAULT CURRENT ALARM Purpose Alarms ground fault current levels which are higher than a preset limit for the application Alarm Mask ENABLE or DISABLE Range 20 to 250 mAmps Procedure Adjust the HIGH GFI ALARM level to the desired value Note that the HIGH GFI ALARM must be enabled in order to adjust the HIGH GFI level 3 8 6 HIGH GROUND FAULT CURRENT ALARM FILTER TIME SETTING V3 11 AND UP Purpose The HIGH GFI ALARM FILTER will prevent HIGH GFI ALARMS from being indicated until a high GFI condition has existed for the duration of the HIGH GFI ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the HIGH GFI ALARM FILTER time to the desired value Note that the HIGH GFI ALARM must be enabled in order to adjust the HIGH GFI ALARM FILTER time Notes e H an alarm condition appears and then disappears before the
11. C 1 TS Wiring d 68 The following drawings provide sample wiring diagrams for the 920 Series control products and optional accessories Please contact your local Tyco Thermal Controls representative for infor mation regarding other available options C 1 1 100 2 PLATINUM RTD WIRING Terminal board Shield 25 Control Source 26 Point A Sense 27 RTD 1 1009 Common 28 Pt RTD Shield 9 Drain Control Source 105 Wht Point A Sense 115 Wht RTD 2 1000 Common 12d Red Pt RTD S Control Point A TS1 and TS2 Wiring Diagram Terminal board Shield Control Source Point B Sense RTD 1 1009 Common Pt RTD Shield 134 Drain Control Source 14g Wht Point B Sense 15 Wht RTD 2 1000 Common 16d Red Pt RTD S Control Point B TS1 and TS2 Wiring Diagram Y Note Temperature sensor manufacturers may use different lead wire colors than those shown in the diagram above Some common color combinations are shown in the table below but others may also be available See sections 3 7 1 on page 32 and 6 2 2 on page 55 for additional details Lead Wire Lead Wire IEC 751 Signal Description Color Scheme 1 Color Scheme 2 Color Scheme 3 Source White White Red Sense White Black Red Common Red Red White C 1 2 1002 NICKEL IRON RTD WIRING C Terminal board E Shield 256 Drain Hana Source 269 Jumper Sense 27 L Common 28 J Shield 95 Drain Control Point A Source 100 Jump
12. Jumpers 1 and J2 are normally supplied by the Factory 2 Terminals 5 and 8 are only supplied when 3 phase versions are ordered from the Factory 3 Remove jumper J2 C 2 3 CONTROLLER POWERED FROM A SEPARATE CIRCUIT 1PH 120 277 Vac S Control power input Trace power in L1 line L1 line Control power in L1 line L1 line 1PH or 3PH Trace power in L2 neutral L2 neutral Trace power input Control power in L2 neutral L2 neutral Trace power out L1 line L1 line Trace power out L2 neutral L2 neutral Trace power out L3 L3 1 2 3 4 Trace power in L3 5 3 6 AW 12063 00 00 MN Notes 1 Jumpers 1 and J2 are normally supplied by the Factory 2 Terminals 5 and 8 are only supplied when 3 phase versions are ordered from the Factory 3 Remove jumpers 1 and J2 70 C 3 Communication Wiring C 3 1 2 WIRE MODEM OPTION C Terminal board Comm 1 6 O Modem Comm 2 T Comm 3 8 d Comm 4 225 Modem Comm 5 23 Ground 24 Drain C C 3 2 2 WIRE 6 485 OPTION Terminal board S 4 Comm 1 65 RXD TXD 4 Comm 2 7 5 Comm 3 8 5 Comm 4 225 RXD TXD Comm 5 23 Ground 24 Drain 6 C 3 3 RS 232 OPTION Terminal board E Comm 1 654 POD Comm 2 Tlga DCD Comm 3 3d rg Comm 4 22 TXD Comm 5 23 RTS Ground 24 Danni C 4 Alarm Output Wiring C 4 1 USED AS A DRY CONTACT G Terminal board 9Vdc Nom l i5 gt
13. Operating at voltages less than design can cause serious loss of heater output The alarming of preset voltage deviations ensures availability of sufficient wattage output Power Limiting The 920 will control the maximum output wattage if the full load power exceeds the specified maximum power setpoint This feature eliminates the need for low voltage transformers in many applications and can assist in standardization of heating cable types SSR options only Autocycling The controller will energize the circuit for 10 seconds at a programmable interval Circuit alarms will be generated at the time of autocycle instead of when the heat is required This feature elim inates the need for a preventive maintenance program as these tests are performed at regular intervals by the controller Temperature Sensor Failure Alarm Both open and shorted sensors are detected and alarmed by the controller 1 3 Modular Components Random Start A startup delay between 0 and 9 seconds ensures that all units do not come on line at the same time Full Digital Communications An optional internal communications interface allows the communication of alarms and analog data to a monitoring system Industry standard RS 232 or RS 485 serial communications are available for applications requiring direct interfacing to other devices The modem version main tains compatibility with legacy products including the GCC 9000 780 Series Group Communi cations Controller
14. all inputs must be activated before the HTC will go into a Load Shedding mode 2 If communications between an HTC and an upstream device such as a GCC or supervisory software are interrupted or if the power has been reset to the HTC the HTC will hold its out put OFF waiting for a Load Shedding command 3 Only if the Low Temperature Alarm is ENABLED 4 For 920 Series controllers a lt Load Shedding message will displayed after the load current reading Appendix E 100 Q Platinum RTD Table 1EC751 1983 100 Q Platinum Resistance Temperature RTD 0 00385 Ohms Ohm C Ohms F c Ohms F E Ohms F E 62 28 139 95 159 18 311 155 248 76 761 405 64 30 130 90 161 04 320 160 250 48 770 410 66 31 121 85 162 90 329 165 252 19 779 415 68 33 112 80 164 76 338 170 253 90 788 420 70 33 103 75 166 61 347 175 255 61 797 425 72 33 94 70 168 46 356 180 257 32 806 430 74 33 85 65 170 31 365 185 259 02 815 435 76 33 76 60 172 16 374 190 260 72 824 440 78 32 67 55 174 00 383 195 262 42 833 445 80 31 58 50 175 84 392 200 264 11 842 450 82 29 49 45 177 68 401 205 265 80 851 455 84 27 40 40 179 51 410 210 267 49 860 460 86 25 81 35 181 34 419 215 269 18 869 465 88 22 22 30 183 17 428 220 270 86 878 470 90 19 13 25 184 99 437 225 272 54 887 475 92 16 4 20 186 82 446 230 274 22 896 480 94 12 5 15 188 63 455 235 275 89 905 485 96 09 14 10 190 45 464 240 277 56 914 490 98 04 23 5 192 26 473 245 279 2
15. 1 4 Controller Assemblies 1 5 Ordering and Configuration Guide Redundant operation is supported allowing a control module to automatically power itself from either of two switch interface modules or both This permits one heat trace circuit to be turned off for maintenance without affecting the operation of the other circuit 1 3 5 COMMUNICATIONS INTERFACE In applications where the user wishes remote configuration capability or wants to communicate trace information and or alarms to another device such as the GCC Group Communications Controller an optional communications interface may be installed in the control module A modem version that maintains compatibility with legacy products is available or other industry standard interfaces such as RS 232 and RS 485 may be specified 1 3 6 SOLID STATE RELAY OUTPUT MODULE In applications where the benefits of solid state control are desired a modular solid state relay SSR is available This component is easily installed on the outside of an enclosure using a sin gle 3 4 NPT knockout and locknut providing a weatherproof seal This allows the heat generated by the SSR to be dissipated directly to the ambient air without increasing the internal tempera ture of the enclosure When applications require two pole or 3 phase switching multiple SSR modules may be ganged together allowing the same component to be used Due to its modular packaging the 920 easily supports single dual or multi
16. ALARM setting for the application Alarm setting too close to normal operating High in rush current from cold start of self regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Low Current Alarms current levels that are less than the LOW CUR RENT ALARM setting Alarm setting too close to normal operating current Low source voltage Damaged or inoperative heating cable Open connection wiring problem SSR or contactor failed open Incorrect CURRENT TURNS RATIO setting High GFI Alarms ground fault current levels that are greater than Alarm setting too close to normal leakage current the HIGH GFI ALARM setting Damaged cable insulation and or moisture present Moisture in junction box Poor splice or termination Moisture provides conductive ground path that allows ground fault current GFI Trip This value sets the upper limit of allowable ground fault Trip setting too normal leakage current leakage Exceeding this link results in the output switch Damaged cable insulation and or moisture present being latched off and the alarm activated to indicate a Moisture in junction box ground fault condition Poor splice or termination Moisture provides conductive ground path that allows ground fault current High Voltage Alarms voltage levels that are greater than the HIGH Alarm setting too close
17. Communication Setup Sub Menu Parameter Factory User HTCBUS Addr factory ID Protocol HTCBUS Baud Rate AUTO Hardware None modem 2 2 if installed Driver Auto Profile Auto Tx Delay 0 02 secs Point Setup Sub Menu Parameter Factory User Tag TAG 32768 Switch Control Mode Proportional Prop Band 4 F 2 C Deadband n a Switch Rating 30 0A Circuit Breaker 30 0A Max Power 7200 W TS CTL Mode TS1 Fail Off TS1 High Limit Disable TS2 High Limit Disable Volt Turns Ratio 1 00 to 1 11 78 Point Setup Sub Menu Continued Current Turns Ratio 1 00 to 1 Autocycle Enable Autocycle Interval 8 Autocycle Units Hours Inhibit Ctl Disable Load Shedding Disable Configuration Mode Main Menu Parameter Control Setpoint Factory User 68 F 20 C TS Alarms Configuration Sub Menu Parameter Factory User TS 1 Fail Enable Lo TS 1 Alarm Enable Lo TS 1 14 F 10 C Hi TS 1 Alarm Enable Hi TS 1 212 F 100 C TS 2 Fail Disable Lo TS 2 Alarm Disable Lo TS 2 Hi TS 2 Alarm Disable Hi TS 2 Latch TS Alarms Yes TS CTL Fail Alarm Enable Other Alarms Configuration Sub Menu Parameter Factory User Lo Load Alarm Enable Lo Load 1 00A Hi Load Alarm Disable Hi Load Hi GFI Alarm Enable Hi GFI 50 ma GFI Trip Alarm Enable GFI Trip 75 ma Lo Volt Alarm Enable Lo Volt 90
18. Dry contact Alarm Relay Bo gt Output Common 2o 71 72 C 4 2 USED AS A SWITCHED DC CONTACT G Terminal board 9Vdc Nom l mE i Alarm Relay 18 Zal 9VDC Switched Common 75 gt On alarm C ej C 4 3 USED TO DRIVE AN OPTIONAL EXTERNAL RELAY Terminal board 9Vdc Nom E g Crydom MS11 CX240D5 Alarm relay E 3 Control AC alarm L15 14 277Vac max switched Common g5 o 4 Input Relay out 2 4 gt Alarm output A a Hi C 4 4 USED TO DRIVE AN OPTIONAL EXTERNAL PILOT LIGHT C Power terminals Trace power in L1 line Control power on L1 line e Trace power in L2 neutral Control power on L2 neutral BIN Terminal board 9Vdc nom er Alarm e _Crydom MS11 CX240D5 Relay T 18 r 1 gt 3 Control AC alarm e Common 22 94 Input Relay out SL ec 2 Switched line L1 C 5 External Input Output Port Wiring C 5 1 EXTERNAL INHIBIT OVERRIDE USING A DRY CONTACT C Terminal board 9Vdc nom 1 Ext contact Input 215 External dry contact ose to activiate inhibit or override mode eaim 2 Close to activiate inhibit id d T o 2kQ max total loop resistance C 5 2 EXTERNAL INHIBIT OVERRIDE USING A DC SIGNAL C Terminal board S 9Vdc nom 15 0S Ext contact Input o D E Common 25
19. The power limiting feature is always enabled when using an SSR output switch and is intended to limit the average amount of power that is applied to the trace circuit The controller measures the voltage and current of the trace circuit and will vary its output switch to limit the amount of power applied to the trace to the value set by the MAXIMUM POWER setting Enabling this alarm will only inform the user that power limiting is currently active Alarm Mask ENABLE or DISABLE Procedure Adjust the MAXIMUM POWER setting to the desired value Enable or disable the alarm as required The POWER LIMITING ALARM need not be enabled to adjust the MAXIMUM POWER set ting VA Notes This is a non latching alarm This alarm is advisory and is normally disabled It will be active if the MAXIMUM POWER set ting is set below the power output level required for temperature maintenance In other words if the circuit demands the maximum power allowed and the alarm is enabled then 41 3 9 Communications Setup 42 this alarm will be indicated and the output switch will pulse ON and OFF to limit the average power output to a value approximately equal to the MAXIMUM POWER setting 3 8 22 SWITCH LIMITING STATUS SSR ONLY Purpose The switch limiting feature is always enabled when using an SSR output switch and provides protection for the output switch Enabling this alarm will only inform the user that switch limiting is currently active and an excessi
20. Thermal Controls releases new firmware to modify or enhance the product significantly new documentation will accompany these releases To ensure that you are using the correct documentation for your particular version of controller please check the firmware version number of the 920 against the version number listed on the front of this manual This can be displayed using the optional 920 Operator Console or a communicating device As subse quent changes are made supplements to this document will be included in manuals shipped after the firmware is released Supplements will make specific reference to the operational or functional changes 1 2 1 DESCRIPTION The 920 Series Heat Tracing Controller controls monitors and communicates alarms and data for one or two heating circuits As a dual point device it offers a complete range of control and monitoring features as well as superior reliability compared to multipoint systems Its modular scalable architecture yields cost effective multipoint assemblies without the expense of addi tional control points that are not required Available for use with external solid state relays SSRs or contactors in either one two or three pole configurations and the ability to switch loads up to 600 Vac makes the 920 the most versatile product on the market 1 2 2 FEATURES A detailed description of available features can be found in Section III of this manual Highlights of specific features are included in
21. With the availability of the heat trace data at the user s fingertips historical trending of temperatures power consumption or other parameters are available for analysis and system optimization CSA C US and Factory Mutual Approved The 920 series of controllers is approved for Class Division 2 Groups A B C D and Zone 2 hazardous locations making it ideal for direct installation in the field This can save the signifi cant expense of wiring back to a centrally located electrical distribution center The 920 series controller is made up of a number of building blocks allowing the ultimate in design flexibility Each component s primary function is described below 1 3 1 CONTROL MODULE The 920 control module forms the heart of a single or dual point heat trace control solution Each plug in module provides all of the intelligence required to control and monitor two inde pendent heat trace circuits It includes indicators for alarm and output status and a connector for use with a 920 Operator Console An internal connector is provided to plug into an optional com munications interface The control module packaging provides a rugged vibration proof design Once it is plugged into a terminal board the module is fastened using the two captive screws included as part of the rear cover It is important that these two screws be securely fastened whenever the module is powered 1 3 2 TERMINAL BOARD The terminal board eases maintenance an
22. a Ext Input Not used Ext Output Not used Flash Alarm Output Yes Alarm Output N C Language English Point B Used Yes Passcode 0 Scroll Delay 0 15 secs Copy Config see user manual Communication Setup Sub Menu Parameter Factory User Protocol HTCBUS HTCBUS Addr factory ID Modbus Addr n a 1 Modbus Sub Addr n a 0 Baud Rate Auto Parity n a None Hardware None modem RS 232 RS 485 n a Driver Auto Profile Auto Tx Delay 0 06 secs n a Parameter may only appear if certain features are enabled Values shown in brackets are Tyco Thermal Controls defaults if the settings are enabled This information defines the default 920 Series control module configuration as set by Tyco Thermal Controls for firmware up to V3 2x These settings are subject to change without notice It is the user s responsibility to verify that all configuration parameters are chosen appropri ately for the intended application 83 Important A information including illustrations is believed to be reliable Users however should independently evaluate the suitability of each product for their particular application Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information and disclaims any liability regarding its use Tyco Thermal Controls only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product and
23. alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e f the user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 7 GROUND FAULT TRIP ALARM Purpose This value sets the upper limit of allowable ground fault leakage current Exceeding this limit will result in the output switch being latched off and the GFI TRIP ALARM activated to indicate a ground fault condition Alarm Mask ENABLE or DISABLE Range 20 to 250 mAmps Procedure If ground fault tripping is desired enable the GFI TRIP ALARM and adjust the GF TRIP CURRENT to the desired value To disable ground fault tripping disable the alarm Note that the GFI TRIP ALARM must be enabled in order to adjust the G F TRIP CURRENT level Caution n order to implement a ground fault trip function all nongrounded power conductors must be opened upon detection of a ground fault condition Note National Electrical Codes require that all legs of non neutral based power sources be opened upon detection of a ground fault Multipole switch configurations should be used on non neutral based power systems Check the requirements with your local electrical authority 3 8 8 LOW VOLTAGE ALARM Purpose Alarms voltage levels that are lower than a preset limit for the applicati
24. corresponding alarm will be indicated fthe user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 14 HIGH RESISTANCE ALARM Purpose Alarms heater resistance levels that have increased from the NOMINAL RESISTANCE set ting by more than the selected amount The HIGH RESISTANCE ALARM may be used to indicate an open or a high resistance connection or when using constant wattage parallel cables may indi cate the failure of one or more heating zones It may also be used to monitor a failed series type cable or connection in 3 phase applications while minimizing nuisance alarms created by voltage fluctuations Alarm Mask ENABLE or DISABLE Range 1 to 25076 deviation from NOMINAL RESISTANCE Procedure Adjust the HIGH RESISTANCE ALARM level to the desired value The HIGH RESISTANCE ALARM must be enabled to adjust the HIGH RESISTANCE deviation Notes Using the LOW CURRENT ALARM feature to ensure that unexpected decreases in current con sumption by the heating cable are alarmed is a reliable method of monitoring the integrity of series type heating cables When using parallel type heaters zoned constant wattage or self regulating or in 3 phase installations the LOW CURRENT ALARM setting must be chosen as close as possible to the lowest expected current to detect failed zones cable degradation or a lost phase The problem with such a clo
25. filter time has expired 5 2 3 PROPORTIONAL AMBIENT SSR CONTROL FOR USE WITH SSRS ONLY When an HTC using an SSR 19 used to control the output using the ambient temperature this control mode should be used Proportional ambient SSR control on the HTC is implemented as follows When using SSRs to directly control the power applied to a heating circuit the output may be switched on off very rapidly The controller implements proportional temperature control on a cycle by cycle basis 50 or 60 Hz power line cycle This algorithm monitors ambient temperature and compares it to the CONTROL SETPOINT temperature If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting power is applied to the trace with a duty cycle of 100 the controller output is fully on 51 e f the temperature sensed by the control sensor is equal to or greater than the CONTROL SET POINT temperature the output will have a duty cycle of 0 the controller output will be off The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0 100 band Proportional Ambient SSR Control Temperature Band Control Sensor Temperature Duty Cycle Setpoint 0 Setpoint proportional band 2 50 Setpoint proportional band 100 Note The load shedding fail safe mode is not supported when u
26. implement their operation This section describes the control modes available in the HTC and how to set their associated parameters There are four SWITCH CONTROL modes associated with the HTC The following is an explanation of their implementation in the controller and the differences between them 5 2 1 PROPORTIONAL CONTROL FOR USE WITH SSRS ONLY Proportional control on the HTC is implemented as follows When using SSRs to directly control the power applied to a trace circuit the output may be switched on off very rapidly The controller implements proportional temperature control on a cycle by cycle basis 50 or 60 Hz power line cycle This algorithm monitors the temperature of the heating circuit and compares it to the CONTROL SETPOINT temperature If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature power is applied to the trace with a duty cycle of 100 the controller output is full on If the temperature sensed by the control sensor is equal to or greater than the CONTROL SETPOINT temperature the PROPOR TIONAL BAND setting the controller output will have a duty cycle of 0 the output will be off The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0 100 band Proportional Control Temperature Band Control Sensor Temperature Duty Cycle Setpoint proportional band
27. in no case will Tyco Thermal Controls or its distributors be liable for any incidental indirect or conse quential damages arising from the sale resale use or misuse of the product Specifications are subject to change without notice In addition Tyco Thermal Controls reserves the right to make changes without notification to Buyer to processing or materials that do not affect compli ance with any applicable specification Tyco and DigiTrace are trademarks of Tyco Thermal Controls LLC or its affiliates WORLDWIDE HEADQUARTERS CANADA LATIN AMERICA TYCO THERMAL CONTROLS TYCO THERMAL CONTROLS TYCO THERMAL CONTROLS 300 Constitution Drive 250 West Street Carlos Calvo 2560 Menlo Park California 94025 1164 Trenton Ontario C1230AAP USA Canada K8V 552 Buenos Aires Argentina Phone 800 545 6258 Phone 800 545 6258 Phone 54 11 4 308 6444 Fax 800 596 5004 Fax 800 596 5004 Fax 54 11 4 308 6445 info tycothermal com www tycothermal com tyco Thermal Controls 10 05 H56874 Previously Pyrotenax doc 20726006 Printed in U S A 2005 Tyco Thermal Controls LLC
28. individually for both Point A and Point B 3 7 1 TEMPERATURE SENSOR 1 FAILURE ALARM Purpose Enabling TS 1 FAILURE will provide indication of an open or shorted failure of TS 1 Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming of a failed first temperature sensor TS 1 as required Notes This failure alarm should be enabled if a temperature sensor is connected to the TS 1 input This alarm is always latched and must be reset by the user 3 7 2 LOW TEMPERATURE SENSOR 1 ALARM Purpose If enabled the LOW TS 1 ALARM allows for alarming of low temperature conditions as sensed by the first temperature sensor TS 1 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the LOW TS 1 ALARM temperature setpoint to the desired value Note that the LOW TS 1 ALARM must be enabled in order to adjust the LOW TS 1 ALARM temperature setpoint Notes This alarm should normally be enabled and the setpoint should be appropriate for the heating application Maintaining a minimum 5 C differential between low temperature alarming and the CONTROL SETPOINT temperature will minimize nuisance alarming due to momentary dips in temperature Another alternative to this is to configure the controller for non latching tem perature alarms This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT tempera ture if fail safe mode uses the temperature from TS 1 3 7 3 HIGH TEMPERA
29. measured since the last time the PEAK LOAD CURRENT was reset This value is written to the controller s nonvolatile mem ory once every 24 hours or whenever any maintenance data is reset by the user Procedure The PEAK LOAD CURRENT may only be reset to zero using a communicating device 4 3 7 PEAK GROUND FAULT CURRENT V3 11 AND UP Note The PEAK GROUND FAULT CURRENT is not displayed on the optional 920 Operator Console Purpose This feature indicates the highest instantaneous ground fault current measured since the last time the PEAK GROUND FAULT CURRENT was reset This current value is written to the controller s nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user Procedure The PEAK LOAD CURRENT may only be reset to zero using a communicating device 4 3 8 EXTERNAL INPUT STATUS V3 11 AND UP Note The EXTERNAL INPUT STATUS is not displayed on the optional 920 Operator Console Purpose This feature indicates the actual status of the external input regardless of the control ler s configuration This can assist the operator who wishes to use the controller s external input to monitor the status of an external dry contact and pass this on to another device Procedure The EXTERNAL INPUT STATUS may only be viewed using a MODBUS capable soft ware package There are several types of control modes in the controller Some of these modes require further explanation in order to fully understand and
30. mechanically and electrically Procedures for config uring and operating the heat trace controller are given in Section 3 on page 18 If the shipment is incomplete there is mechanical damage a defect or the controller does not pass the electrical performance tests notify your Tyco Thermal Controls representative If the shipping container is damaged or the cushioning material shows signs of stress notify the carrier as well as your Tyco Thermal Controls representative Keep the shipping materials for the carrier s inspection The standard 920 controller using solid state relays is suitable for Class Division 2 Groups A B C D and Zone 2 hazardous areas Hazardous areas are defined by Article 500 of the National Electrical Code and Section 18 of the Canadian Electrical Code Contactor based assemblies are suitable for use in ordinary non hazardous areas only Caution Many wiring configurations will use more than one power source and all must be de energized prior to performing any maintenance on a controller circuit The operating environment should be within the limitations described in the 920 heat trace con troller specifications outlined in Appendix A on page 61 The wide ambient operating temperature range of the controller permits installation in any con venient location Considerations should include expected atmospheric conditions accessibility for maintenance and testing the location of existing conduits and hazardous are
31. no user serviceable parts in the 920 series controller or accessories except lamps in optional alarm pilot lights The unit is designed to be modular and easily changed out in the field Modules appearing inoperative should be returned to the nearest Tyco Thermal Controls Service Center for service Warning Tampering with the 920 components without approval from Tyco Thermal Controls could result in the product s warranty being void Appendix A Specifications Specifications are 25 C unless otherwise noted and are subject to change without notice System Ratings Storage ambient 40 F to 185 F 40 C to 85 C Approvals CSA C US Factory Mutual Classification e CI I Div 2 Grp A B C D and Ex nA IIA IIB IIC Zone 2 e SSR Version T code T4 T3A with optional pilot light Ordinary locations SSR and contactor versions 920 Series Wiring Terminal Ratings Terminal board 28 12 AWG strip length 0 22 Switch interface 28 14 AWG strip length 0 33 Power terminals 30 A 22 8 AWG strip length 0 47 torque 16 0 Ib in 60 A 14 6 AWG strip length 0 47 torque 26 5 Ib in 920 Series Control Module per control point Operating temperature 40 F to 140 F 40 C to 60 C Power requirement 9 Vdc nominal 600 ma maximum Control modes Proportional deadband proportional ambient SSR propor tional ambient contactor modes adjustable 2 F to 90 F
32. of the 920 controller cur rent ground fault voltage and resistance These parameters must be set up individually for both Point A and Point B 3 8 1 LOW LOAD CURRENT ALARM Purpose Alarms current levels that are lower than a preset limit for the application Monitoring for lower than expected current levels may be an effective means of continuity monitoring See also HIGH RESISTANCE ALARM in section 3 8 14 on page 39 Alarm Mask ENABLE or DISABLE Range 0 3 to 100 0 amps CURRENT TURNS RATIO 1 00 Procedure Adjust the LOW CURRENT ALARM level to the desired value Note that the LOW CUR RENT ALARM must be enabled in order to adjust the LOW CURRENT ALARM level Also note that the LOW CURRENT ALARM level is affected by the CURRENT TURNS RATIO setting The absolute maximum adjusted LOW CURRENT ALARM level is 300 0 amps The absolute minimum adjusted LOW CURRENT ALARM level is 0 1 amps See section 3 5 22 on page 26 for more information regarding the CURRENT TURNS RATIO function Notes V3 00 only To minimize nuisance LOW CURRENT ALARMS the HTC must detect a current level less than the LOW CURRENT ALARM setpoint for a period longer than approximately 20 consecutive sec onds e For series type heating cables adjusting the LOW CURRENT ALARM to 50 of full load current will properly alarm a problem and reduce nuisance alarms due to voltage dips Parallel heaters should be adjusted to a level as close as possible to full load current
33. on conduit connections to provide a suitable ground Grounding terminals screws are provided for connection of system ground leads Proper system grounding is required for safe and correct operation of the controller s protection features 2 7 6 INPUT POWER The 920 controller may be powered directly from the trace voltage 120 Vac to 277 Vac through a step down transformer or from a separate circuit The same wiring terminal assign ments are used in all configurations as defined below Power Connections Terminal No Line L1 power input 1 Line L1 Control Power Input Neutral L2 Power Input 2 3 Neutral L2 Control Power Input 4 L3 Power Input 3Ph only 5 6 7 8 Line L1 Output to Trace Neutral L2 Output to Trace L3 Output to Trace 3Ph only Note that terminals 5 and 8 are only used for implementing 3 phase switching this is true for both SSR and contactor configurations When powering the controller directly from the incoming trace power 120 Vac to 277 Vac jumpers are installed between terminals 1 and 2 and 3 and 4 This is the standard factory config uration When the controller is to be powered from another voltage source the jumpers between terminals 1 and 2 and 3 and 4 should be removed and the controller power connected to termi nals 2 and 4 In applications where a neutral based 4 wire 3 phase source is available the controller may be powered from one line to neutral connection while th
34. or a combination of the three temperatures See section 3 5 12 on page 24 of this manual for further details regarding the TS CONTROL MODE settings 4 2 2 TS 1 TEMPERATURE Purpose This temperature is the value the controller reads from the RTD connected to its TS 1 input Depending on the TS CONTROL MODE it may be used to determine the CONTROL TEMPERA TURE see section 4 2 1 on page 47 47 48 Note V3 11 and up If the TS 1 input is not being used by the controller the TS 1 TEMPERATURE is not displayed Note Changing the TS Type will affect the temperature reading 4 2 3 TS 2 TEMPERATURE Purpose This temperature is the value that the controller is reading from the RTD connected to its TS 2 input Depending on the TS CONTROL MODE it may be used to determine the CONTROL TEMPERATURE see section 4 2 1 on page 47 Note V3 11 and up If the TS 2 input is not being used by the controller the TS 2 TEMPERATURE is not displayed Note Changing the TS Type will affect the temperature reading 4 2 4 LOAD CURRENT Purpose The LOAD CURRENT reading indicates the average current being drawn by the heating cable Note The controller calculates the LOAD CURRENT using the current sensed by the switch inter face module multiplied by the CURRENT TURNS RATIO to yield an adjusted current value 4 2 5 RESISTANCE Purpose Resistance is calculated using the average adjusted voltage reading divided by the average adjusted current rea
35. point configura tions Factory standard assemblies are available in a variety of enclosure types and panels made up of multiple points are also available Refer to the Ordering Guide in section 1 5 on page 10 for a sample listing of available configurations If your application requires a customized solution please contact your Tyco Thermal Controls representative for help in specifying an assembly suited to your particular requirements 920 series control assemblies are ordered as three separate items Enclosure assembly Control module s Optional operator One for every two circuits console s Fig 1 6 920 series control assemblies Tyco Thermal Controls maintains a shelf stock of enclosure assemblies control modules and consoles All other enclosure assemblies are built to order Not all options may be listed Contact your local representative for any special applications you may have 1 5 1 ENCLOSURE ASSEMBLY Enclosure Assemblies Description Catalog number Part number Weight Ibs DigiTrace 920 controller 2 Pt in a 14 x 12 x 8 FRP enclosure 920 E4FWL SIS302 SS3102 HTC CON 10160 010 27 with window and quick release latches control module and oper ator console 1P 30 A 277 V SSR pt Controls two circuits each with a 1 pole solid state relay Approved for Class 1 Div 2 areas DigiTrace 920 controller 2 Pt in a 14 x 12 x 8 FRP enclosure 920 E4FWL SIS302 SS3102 HTC485 CON 10160 011 27 w
36. protective device as defined by the National and Canadian Electrical Codes NEC and CEC A protective device such as a circuit breaker or fuse must be included as part of a proper design and be selected in accordance with the requirements defined in the National Electrical Code NEC and or the Canadian Elec trical Code CEC The controller cannot protect the SSR from short circuits or excessive overcurrent condi tions Always ensure that the power is off prior to performing any maintenance or trouble shooting of the heating circuit Verify that no damage has occurred to the cable or the controller prior to re energizing the circuit Alarm Mask ENABLE or DISABLE Procedure Adjust the SWITCH CURRENT RATING setting to the actual current rating of the SSR Enable or disable the alarm as required Note that the OVERCURRENT TRIP ALARM does not have to be enabled in order to adjust the SWITCH CURRENT RATING setting Note This alarm should be left enabled since an overcurrent trip condition would normally rep resent a serious problem This is a factory set alarm value and disabling the alarm does not dis able the overcurrent trip function In some applications the use of self regulating cables will produce very high in rush currents during cold startup These currents may exceed the overcur rent trip limit and the controller will not be able to soft start the trace circuit If this condition per Sists please contact your nearest sales office f
37. temperature and or control the average amount of current power the tracer uses separate LED is provided for Point A and Point B ALARM The ALARM LEDs will flash approximately once per second when the controller has detected an alarm condition A separate LED is provided for Point A and Point B TRANSMIT The TRANSMIT LED Tx flashes when the controller is sending information over its communications port to another device This LED is only used when an optional communications interface is installed RECEIVE The RECEIVE LED Rx flashes when the controller is receiving information over its communications port from another device This LED is only used when an optional communica tions interface is installed POWER Indicates the module is powered on Note Older versions of the controller may not have this LED The optional 920 Operator Console provides a menu driven alphanumeric interface to ease con figuration and troubleshooting The following features are part of the controller s programming but are only used in conjunction with the 920 Operator Console For a detailed description of each of the console features and operating instructions refer to the separate DigiTrace 920 Series HTC Operator Console Installation and Operating Instructions Tyco Thermal Controls reference H56903 19 3 4 920 Functions 3 5 Control Point Setup 20 The sections that follow explain the various functions of the 920 contro
38. the LATCH TS ALARMS setting to the desired mode latching or nonlatching Notes e lf your application is subject to periodic situations where cold or hot product is part of the process it may be appropriate to configure the HTC for nonlatching temperature alarms to avoid nuisance alarms If it is important to be aware of any temperature alarm conditions that may have existed in a pipe the HTC should be configured for latching temperature alarms This setting does not affect the TS FAILURE ALARMS these are always latching 3 7 10 CONTROL TEMPERATURE SENSOR FAILURE ALARM Purpose CONTROL TS FAILURE ALARM indicates a failure of the temperature sensor designated as the control sensor One of eleven TS CONTROL MODES may be selected These modes determine which TS INPUT and or EXT INPUT is designated to provide the control temperature See section 3 5 12 on page 24 for a full description of the temperature sensor control designations Alarm Mask ENABLE or DISABLE Procedure Enable or disable the alarming of a failure of the designated control temperature sen sor as required Note This alarm should always be enabled If the controller experiences a CONTROL TS FAILURE it will turn the output off or on as specified by TS FAIL MODE until this alarm is cleared If the TS CONTROL MODE uses the EXTERNAL INPUT a CONTROL TS FAILURE is self clearing i e is non latching This Section defines the nontemperature related alarming functions
39. to normal operating voltage VOLTAGE ALARM setting Incorrect wiring Incorrect VOLTAGE TURNS RATIO Power surge Low Voltage This alarms voltage levels which are less than the Alarm setting too close to normal operating voltage 58 LOW VOLTAGE ALARM setting Damaged power cable Incorrect VOLTAGE TURNS RATIO Brown out conditions Loss of power to the circuit 6 3 Common Alarms What to look for Continued Alarm Description Cause of Alarm Excessive in rush current If the controller is unable to start the cable due to high Overcurrent Trip current or after attempting to soft start it the controller trips off its output switch Incorrect wiring Damaged cable Switch rating set too low Incorrect CURRENT TURNS RATIO setting Switch Failure HTC Reset This alarm will indicate that the controller senses current flow when the output switch should be off e Some other device has energized the heat trace cable Output switch has failed This alarm is latched when power is restored after an interruption Used to identify intermittent power losses Circuit breaker tripped Power line transient Power Limiting This alarm indicates that the solid state relay is limiting the average amount of power that is applied to the trace circuit as defined by the MAXIMUM POWER setting Power applied to trace circuit is being limited to the MAXI MUM POWER setting Incorrect VOLTAGE a
40. 0 Setpoint proportional band 2 50 Setpoint 100 5 2 2 DEADBAND CONTROL FOR USE WITH EXTERNAL CONTACTORS Deadband control on the HTC is implemented as follows When using the HTC in an application where the controller is used to open and close a contactor proportional control cannot be used In these cases a deadband control algorithm is used The output duty cycle is not controlled instead the output is either fully on or completely off The user can set the DEADBAND value The controller monitors the temperature of the trace circuit and compares it to the CONTROL SETPOINT temperature as in the proportional control If the con trol sensor temperature is above the CONTROL SETPOINT temperature by more than the DEAD BAND value the output is turned off If the control sensor temperature falls below the CONTROL SETPOINT temperature the output is turned on This is a simple control algorithm but it works very effectively in heat trace applications where the temperature of a traced system changes rel atively slowly Deadband Control Temperature Band Control Sensor Temperature Output State Setpoint deadband Off Setpoint On When the control sensor temperature is within the deadband the output does not change its state Also when using deadband control a contactor is not allowed to toggle faster than every two seconds If an AC alarm with an alarm filter time greater than 0 is detected the contactor will not toggle until the alarm
41. 3 923 495 100 0 32 0 194 07 482 250 280 90 932 500 101 95 41 5 195 88 491 255 282 56 941 505 103 90 50 10 197 69 500 260 284 22 950 510 105 85 59 15 199 49 509 265 285 87 959 515 107 79 68 20 201 29 518 270 287 53 968 520 109 73 77 25 203 08 527 275 289 18 977 525 111 67 86 30 204 88 536 280 290 83 986 530 113 61 95 35 206 67 545 285 292 47 995 535 115 54 104 40 208 45 554 290 294 11 1004 540 117 47 113 45 210 24 563 295 295 75 1013 545 119 40 122 50 212 02 572 300 297 39 1022 550 121 32 131 55 213 80 581 305 299 02 1031 555 123 24 140 60 215 57 590 310 300 65 1040 560 125 16 149 65 217 35 599 315 302 28 1049 565 127 07 158 70 219 12 608 320 303 91 1058 570 128 98 167 75 220 88 617 325 305 53 1067 575 130 89 176 80 222 65 626 330 307 15 1076 580 132 80 185 85 224 41 635 335 308 76 1085 585 134 70 194 90 226 17 644 340 310 38 1094 590 136 60 203 95 227 92 653 345 311 99 1103 595 138 50 212 100 229 67 662 350 313 59 1112 600 140 39 221 105 231 42 671 355 315 20 1121 605 142 29 230 110 233 17 680 360 316 80 1130 610 144 17 239 115 234 91 689 365 318 40 1139 615 146 06 248 120 236 65 698 370 319 99 1148 620 147 94 257 125 238 39 707 375 321 59 1157 625 149 82 266 130 240 13 716 380 323 18 1166 630 151 70 275 135 241 86 725 385 324 76 1175 635 153 58 284 140 243 59 734 390 326 35 1184 640 155 45 293 145 245 31 743 395 327 93 1193 645 157 31 302 150 247 04 752 400 329 51 1202 650 Appendix F 100 Q Nickel Iron RTD Table
42. 330 165 288 6 585 307 112 5 80 26 191 1 335 168 290 8 590 310 113 8 85 29 192 9 340 171 293 1 595 312 115 2 90 32 194 5 345 173 295 2 600 315 116 5 95 35 196 4 350 176 297 5 605 318 117 9 100 37 198 2 355 179 299 8 610 321 119 2 105 40 199 9 360 182 301 4 615 323 120 6 110 43 201 7 365 185 303 7 620 326 122 0 115 46 203 5 370 187 306 0 625 329 123 4 120 48 205 3 375 190 308 3 630 332 124 8 125 51 207 2 380 193 310 6 635 335 126 2 130 54 109 0 385 196 312 2 640 337 127 6 135 57 210 8 390 198 314 5 645 340 129 0 140 60 212 7 395 201 316 8 650 343 130 5 145 62 214 5 400 204 319 1 655 346 131 9 150 65 216 4 405 207 320 6 660 348 76 Appendix G Factory Default Configuration Sheets G 1 Configuration Sheet V3 00 The following defines the default 920 Series control module configuration as set by Tyco Ther mal Controls for firmware V3 00 These settings are subject to change without notice It is the user s responsibility to verify that all configuration parameters are chosen appropriately for the intended application Note It is recommended that all parameters common to both Control Points A and B be programmed first Common Setup Sub Menu Parameter Factory User Temp Units SE Firmware Version V3 0 n a Ext Contact Input Not used Ext Contact Output Not used Flash Alarm Output Yes Alarm Output State N C Language English Point B Used Yes Passcode 0
43. 5 LOW TEMPERATURE SENSOR 2 ALARM Purpose If enabled the LOW TS 2 ALARM allows for alarming of low temperature conditions as sensed by the second temperature sensor TS 2 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 60 C to 570 C Procedure Adjust LOW TS 2 ALARM temperature setpoint to the desired value Note that the LOW TS 2 ALARM must be enabled in order to adjust the LOW TS 2 ALARM temperature setpoint KA Notes e If no second sensor is installed this alarm should be disabled This alarm should be enabled and the setpoint should be appropriate for the heating application Maintaining a minimum 5 C differential between low temperature alarming and the CONTROL SETPOINT temperature minimizes nuisance alarming due to momentary dips in temperature Another alternative to this is to configure the controller for non latching temperature alarms This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT tempera ture if fail safe mode uses the temperature from TS 2 3 7 6 HIGH TEMPERATURE SENSOR 2 ALARM Purpose If enabled the HIGH TS 2 ALARM allows for alarming of high temperature conditions as sensed by the second temperature sensor TS 2 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the HIGH TS 2 ALARM temperature setpoint to the desired value Note that the HIGH TS 2 ALARM must be enabled in order to adjust the HIGH TS 2 ALARM temperature setpoint
44. Both of the LOW TS ALARMS are inactive if the INHIBIT mode is active 3 5 27 OVERRIDE SOURCE V3 11 AND UP Purpose An override signal can be sent to the HTC from one of two sources This override signal can be used to override the controller s temperature control and force the output switch off or on This is especially useful when the user wishes to turn a controller or a group of controllers off over the summer months during maintenance or when a line is flowing and does not require heating Setting REMOTE or EXT INPUT Procedure If the override signal will be generated remotely and received by the HTC via the optional communications interface select REMOTE as the OVERRIDE SOURCE If the override sig nal will be received by the HTC via the external input terminals on the 920 terminal board select EXTERNAL INPUT as the OVERRIDE SOURCE Notes ef the EXTERNAL INPUT is not configured as either INHIBIT or FORCE ON then OVERRIDE SOURCE will always automatically be set to REMOTE See section 3 6 3 on page 29 for further details e If the autocycle feature is enabled it will continue to function even when an INHIBIT override signal is being received as long as load shedding is not active Fail safe mode is inactive if an INHIBIT override signal is being received Load shedding and fail safe mode are inactive if a FORCE ON override signal is being received Only the LOW TS ALARMS for temperature sensors used by the TS CONTROL MODE ar
45. DigiTrace DigiTrace 920 Series Heat Trace Controller Installation Operating and Maintenance Manual Firmware versions up to V3 2X Document H56874 SS ALA PS EE T ef g tyco Thermal Controls Table of Contents Introdiictioli a a a PRRD NEE E AC 5 GERA ss npaka BINABAON BR a SE EE 5 Limited War ra a 5 Warranty Exclusion Disclaimer 200 000 5 Exclusive Remedie S esci ines 5 Conducted and Radiated Emissions FCC DOC Statement of Compliance 5 What S NBW a AA e Reise a a a 6 New Controller Features 6 New Operator Console Features ccc eect 7 Section 1 VerVIeW saie ev e Dn ii Bark o deu a G 7 1 1 Controllers Covered by this Manual 7 1 2 Product OverVieW ee we NAGA AE ems Ferd SE 7 i3 9 1 4 Controller Assemblies 10 1 5 Ordering and Configuration Guide 10 Section 2 Installation and Wiring llle 12 2 1 1110600010 ore i ott EUR Pb dwelt ou Ra a Die c diode eed AS 12 2 2 Initial InSpectiOn ERES NEEN e dds Peed ER DE 12 2 3 Operator Safety Considerations 12 2 4 Opera
46. ED When using the terminal board these terminals are marked as follows Terminal No Description 25 Point A Shield 26 Point A TS 1 Source WHT 27 Point A TS 1 Sense WHT 28 Point A TS 1 Common RED 9 Point A Shield 10 Point A TS 2 Source WHT 11 Point A TS 2 Sense WHT 12 Point A TS 2 Common RED 29 Point B Shield 30 Point B TS 1 Source WHT 31 Point B TS 1 Sense WHT 32 Point B TS 1 Common RED 13 Point B Shield 14 Point B TS 2 Source WHT 15 Point B TS 2 Sense WHT 16 Point B TS 2 Common RED The RTD manufacturer will typically color code the leads with the source and sense being the same color and the common a different color Ensure that the RTD extension wire shield is termi nated at one end only normally using the terminal block provided at the terminal board Note Some RTDs may have the Sense wire color coded as Black 2 Questionable Temperature If you feel that the indicated or displayed temperature is not correct the controller and the RTD can be quickly checked for correct operation To verify the RTD Turn off the power to the controller before proceeding e Disconnect the RTD wiring from the input terminals Tocalculate the temperature indicated by the RTD measure the resistance from source white wire or sense white wire to common red wire and subtract the resistance measured between source and sense This will give a compensa
47. Generally the voltage readings will be within 3 Vac to 5 Vac when shipped from Tyco Thermal Controls If more accurate voltage readings are desired they may be adjusted as part of the initial setup of the controller This requires measurement of the trace volt age using a multimeter and adjusting the VOLTAGE TURNS RATIO setting to arrive at more accu rate voltage readings See section 3 5 21 on page 26 2 9 2 SWITCH RATING SETUP SSR ONLY The 920 series control module is ordered and shipped as a separate item from the enclosure assembly This prevents Tyco Thermal Controls from predetermining the SWITCH CURRENT RATING settings since various types of output switches are available The user should verify that the switch current ratings are set properly for the rating of the solid state relays that are included as part of the enclosure assembly Refer to section 3 5 7 on page 22 for more information on the SWITCH CURRENT RATING setting Tyco Thermal Controls default setting is defined in Appendix F on page 76 Section 3 Programming and Configuration 3 1 Introduction This section provides complete operating and setup instructions for the 920 Series Heat Tracing Controller The text describes each available function in detail its purpose valid range settings the procedure for use and some operational tips and suggestions While configuring the controller it is important to remember that the 920 series controller is a two control point de
48. IGH RESISTANCE ALARMS see sections 3 8 13 on page 38 and 3 8 15 on page 39 Alarm filtering will prevent an alarm from being indicated until the alarm condition has existed for the duration of the alarm filter time Two new SWITCH CONTROL MODES have been added for use with Ambient Temperature control Proportional Ambient SSR Proportional Ambient Contactor see sections 3 5 3 on page 21 and 5 2 on page 50 e ASCII and RTU ModBus communications protocol support see section 3 9 1 on page 42 e Support for an isolated 2 wire RS 485 communications interface see section 1 4 5 e A3 phase power calculation feature has been included for use with balanced Y connected heating loads see section 3 5 10 on page 23 ATemperature Sensor TS Fail Mode feature is now available to allow the output to be forced ON or OFF when a control temperature failure occurs see section 3 5 11 on page 23 e ATEMPBUS feature to allow one master 920 controller to share its temperature sensor information with up to 25 slave controllers up to 50 control points This includes the addition of three TS CONTROL MODES see sections 3 5 12 on page 24 and 5 4 on page 53 e Support for 100 ohm nickel iron RTDs along with the standard 100 ohm platinum types see sections 3 5 13 on page 24 and 3 5 16 on page 25 Manual voltage source selection see section 3 5 19 on page 26 Support for FORCE ON and FORCE OFF modes using the EXTERNAL i
49. INT TEMPERATURE that may be set using the optional 920 Operator Console The CONSOLE SETPOINT MINIMUM may only be set using a communicating device such as the Model 780 GCC 9000 See the 780 GCC 9000 manual for the proper procedure The following section describes the setup parameters that are common for both of the two con trol points Point A and Point B These parameters need only be configured once to define their operation for both control points 3 6 1 TEMPERATURE DISPLAY UNITS Purpose This allows selection of the type of temperature units to display when using the 920 Operator Console All temperature related values will be displayed in the selected units Note This setting will not affect the temperature units displayed at a 780 GCC 9000 Group Com munications Controller The GCC may be set independently Setting DEGREES C or DEGREES F Procedure Adjust the setting to the desired temperature units F or C Note To minimize possible confusion temperature units should be set the same on the HTC and any other communicating devices 3 6 2 VERSION OF FIRMWARE AND HARDWARE Purpose The first three digits of the version number indicate the revision level of the firmware programmed into the controller As new features are added to the HTC the firmware revision level is incremented to allow the user to determine which features are available for the particular unit being used The fourth digit V3 11 and up only indicates the type o
50. NAL RESISTANCE setting e Adjust the CONTROL SETPOINT temperature to turn on the output switch Allow the load to come up to design temperature and its power consumption to stabilize Using the 920 Operator Console access the RESISTANCE reading and record its value Return the CONTROL SETPOINT temperature to its proper setting Enter the recorded resistance value as the NOMINAL RESISTANCE setting Note The setup procedure outlined above may have to be repeated a number of times to arrive at a correct nominal resistance setting This value will be affected by the heating cable tempera ture which in turn is affected by ambient temperature insulation level a full or empty pipe or vessel etc 3 8 17 OVERCURRENT TRIP ALARM SSR ONLY Purpose The overcurrent trip feature is always enabled when using an SSR output switch and is used to provide protection for the output switch Enabling this alarm will only inform the user of an excessively high current condition and that the output switch has been latched off During a high current condition the controller attempts to soft start a heating cable by a technique involv ing measured in rush current and the SWITCH CURRENT RATING If the controller is unable to start the cable it will eventually trip its output switch off and will not retry or pulse its output switch again At this point the OVERCURRENT TRIP ALARM is latched on Notes e The controller is nota safety cutout or an overcurrent
51. NTROL for V3 00 must be enabled Notes e When used with the INHIBIT FORCE ON feature a contact closure sensed by the EXTERNAL INPUT will initiate the INHIBIT FORCE ON mode An open input will cause the controller to revert to normal temperature control operation One possible use of the INHIBIT feature is to use an external device such as a flow meter to provide a contact closure if there is flow in a line As long as the line has adequate flow the heating will be off INHIBITed from operating See Appendix C on page 68 for typical connection diagrams when using this input e EXTERNAL INPUT must be set to INHIBIT or FORCE ON before OVERRIDE SOURCE for V3 11 can be set to EXT INPUT or INHIBIT CONTROL for V3 00 can be edited For V3 11 and up set ting EXTERNAL INPUT to NOT USED or TEMPBUS will automatically set OVERRIDE SOURCE to REMOTE 3 6 4 EXTERNAL OUTPUT PORT Purpose The EXTERNAL OUTPUT port can be programmed to allow Point A to function as a mas ter 920 HTC to control up to 25 slave 920 HTC units A master can either force its slaves to override their temperature control and force their output switch off INHIBIT or it can send its control temperature to its slaves so they can do their own temperature control using this tem perature TEMPBUS An INHIBIT master may be useful when a number of slave controllers use their own RTDs but are to be turned off based on the ambient temperature This
52. NTROL USING TS 2 FAIL TO TS 1 CONTROL ON AVERAGE FAIL OFF ON CONTROL ON AVERAGE FAIL TO GOOD CONTROL ON LOWEST FAIL OFF ON CONTROL ON LOWEST FAIL TO GOOD The following are only available in V3 11 CONTROL USING EXT INPUT FAIL OFF ON CONTROL USING EXT INPUT FAIL TO TS 1 CONTROL USING EXT INPUT FAIL TO TS 2 Where OFF ON Controller s output switch turned OFF or ON as determined by the TS FAIL MODE Example With a T5 CONTROL MODE of CONTROL ON AVERAGE FAIL TO GOOD the controller will measure both sensors TS 1 and TS 2 averaging the two temperature value display the results and cycle the heater ON or OFF to maintain the CONTROL SETPOINT temperature This is the pri mary control mode If either sensor should fail the controller will transfer control to the remain ing good sensor and generate the appropriate TS 1 or TS 2 FAILURE ALARM assuming that the alarm is enabled The temperature will now be maintained based on this measured value If the remaining good sensor fails the controller will turn the heater OFF or ON as determined by the TS FAIL MODE setting The appropriate TS 1 or TS 2 FAILURE ALARM will be also be generated Procedure Select the control mode that best suits the application Notes Ensure that TS FAILURE ALARMS are enabled See sections 3 7 1 on page 32 3 7 4 on page 32 and 3 7 10 on page 34 for a complete explanation of RTD failure detection in the HTC e fthe selected TS CONTROL MODE uses th
53. PBUS slave The EXTER NAL INPUT should be set to TEMPBUS then the point s TS CONTROL MODE must be set to a mode using the EXTERNAL INPUT The slave controller will perform its own temperature control using the control temperature of the master If a TEMPBUS slave does not receive a control temperature from a TEMPBUS master at least once every 15 seconds then a CONTROL TS FAILURE ALARM will occur This alarm is non latching for TEMPBUS slaves and will be cleared automatically once a control temperature is received again Point B can be a slave to Point A of the same controller 4 Note Other features that require the use of the EXTERNAL INPUT INHIBIT or OVERRIDE may not be used at the same time as the TEMPBUS slave feature Section 6 Troubleshooting 6 1 Operator Checks Upon receipt of the controller or to check the controller for an indication of normal operation follow the operational procedures shown below These procedures are designed to familiarize the operator with the controller and to provide an understanding of its operation To determine if a fault is associated with the heat tracing wiring or the controller it is necessary to troubleshoot the wiring and tracer circuit If the fault remains remove power from the control ler and exchange it with another controller This may require some reprogramming of the new HTC If the fault clears exchange the controller on an
54. RRENT RATING setting is affected by the CURRENT TURNS RATIO setting The absolute maximum adjusted SWITCH CURRENT RATING setting is 300 0 amps The absolute minimum adjusted SWITCH CURRENT RATING setting is 0 1 amps See section 3 5 22 on page 26 for more information regarding the CURRENT TURNS RATIO function 3 5 8 CIRCUIT BREAKER CURRENT RATING SETTING SSR ONLY Purpose The CIRCUIT BREAKER CURRENT RATING setting helps prevent in rush induced nuisance tripping of the circuit breaker immediately upstream of the controller The HTC evaluates the square of the current related to time I2T and adjusts the output duty cycle accordingly limiting the amount of current to an acceptable level Range 0 3 to 100 0 amps CURRENT TURNS RATIO 1 00 Procedure Adjust the CIRCUIT BREAKER CURRENT RATING setting to the heating circuit breaker size i e 30 0 amps Note that the CIRCUIT BREAKER CURRENT RATING setting is affected by the CURRENT TURNS RATIO setting The absolute maximum adjusted CIRCUIT BREAKER CURRENT RAT ING setting is 300 0 amps The absolute minimum adjusted CIRCUIT BREAKER CURRENT RATING setting is 0 1 amps See section 3 5 22 on page 26 for more information regarding the CURRENT TURNS RATIO function Note This feature should not be used to reduce the size of a circuit breaker or increase the max imum heating cable length It can be quite effective in preventing nuisance trips due to incorrect design or factors outside those considere
55. Sheet V3 00 cece cece rr 77 G 2 920 Series HTC Configuration Sheet V31x eee eee 80 Introduction Certification Limited Warranty Warranty Exclusion Disclaimer Exclusive Remedies Installation and Maintenance Instructions for Firmware Versions up to and Including V3 2X This manual provides information pertaining to the installation operation testing adjustment and maintenance of the DigiTrace Model 920 Series Heat Trace Control and Monitoring products Additional copies of the operating manual may be ordered separately through your Tyco Thermal Controls representative or online at www tycothermal com using the document number H56874 Notice The information contained in this document is subject to change without notice Tyco Thermal Controls certifies that this product met its published specifications at the time of shipment from the Factory This Tyco Thermal Controls product is warranted against defects in material and workmanship for a period of 18 months from the date of installation or 24 months from the date of purchase whichever occurs first During the warranty period Tyco Thermal Controls will at its option either repair or replace products that prove to be defective For warranty service or repair this product must be returned to a service facility designated by Tyco Thermal Controls The Buyer shall prepay shipping charges to Tyco Thermal Controls and Tyco Thermal Controls shall pay shipping charges t
56. TURE SENSOR 1 ALARM Purpose If enabled the HIGH TS 1 ALARM allows for alarming of high temperature conditions as sensed by the first temperature sensor TS 1 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 60 C to 570 CF Procedure Adjust the HIGH TS 1 ALARM temperature setpoint to the desired value Note that the HIGH TS 1 ALARM must be enabled in order to adjust the HIGH TS 1 ALARM temperature setpoint unless the TS 1 HIGH LIMIT CUTOUT feature is enabled Note This alarm should only be used for applications involving a product that is sensitive to over temperature General use may result in nuisance alarms due to the outflow of hot product or steam This may be a case where the alarm should be enabled and nonlatching temperature alarming used A high temperature condition resulting from a forced on failure of the heating cir cuit should first be alarmed by the SWITCH FAILURE ALARM See section 3 8 18 on page 40 for more information 3 7 4 TEMPERATURE SENSOR 2 FAILURE ALARM Purpose Enabling TS 2 FAILURE provides indication of an open or shorted failure of TS 2 Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming of a failed second temperature sensor TS 2 as required ra Notes PA e lf no second sensor is installed disable this alarm This failure alarm should be enabled if a second temperature sensor is connected to the TS 2 input This alarm is always latched and must be reset by the user 3 7
57. TURE SENSOR CONNECTIONS Use shielded twisted three conductor wire for the extension of RTD leads The wire size should ensure that the maximum allowable lead resistance is not exceeded Shields on RTD wiring should be grounded at the controller end only using the terminals provided Temperature Sensors Terminal No Point A Shield 25 Point A TS 1 Source WHT 26 Point A TS 1 Sense WHT 27 Point A TS 1 Common RED 28 Point A Shield 9 Point A TS 2 Source WHT 10 Point A TS 2 Sense WHT 11 Point A TS 2 Common RED 12 Point B Shield 29 Point B TS 1 Source WHT 30 Point B TS 1 Sense WHT 31 Point B TS 1 Common RED 32 Point B Shield 13 Point B TS 2 Source WHT 14 Point B TS 2 Sense WHT 15 Point B TS 2 Common RED 16 2 1 2 ALARM RELAY CONNECTIONS The alarm output relay is a programmable dry contact output It may be programmed for N O N C steady or flashing operation and is typically used to annunciate an alarm to an external device such as a DCS PLC etc Note The alarm relay is intended to be used for switching low voltage low current signals Do not use this relay to directly switch line voltages Ensure that your application stays within the ratings of the relay contacts as defined in Appendix A on page 61 The alarm relay may also be used in conjunction with the 9 Vdc source to switch an external line voltage relay to drive a local pilot light etc Ref
58. V High Volt Alarm Enable Hi Volt 270 V Nominal Resist 6 00 Q Lo Resist Alarm Disable Lo Resist Hi Resist Alarm Disable Hi Resist Overcurrent Trip Enable Switch Fail Alarm Enable HTC Reset Alarm Disable C B Limit Alarm Disable Power Limit Alarm Disable Switch Limit Alarm Disable EEROM Data Fail Disable 79 G 2 920 Series HTC Configuration Sheet V3 1X and V3 2X 80 Most commonly changed setting Note Select temperature units before any other settings are entered Configuration Mode Main Menu Parameter Factory User Control Setpoint 68 F 20 C Lo TS 1 14 F 10 C Lo Load 1 0A Hi GFI 50 mA GFI Trip 75 mA TS Alarms Configuration Sub Menu Parameter Factory User TS 1 Fail Enable LoTS 1 Enable Lo TS 1 14 F 10 C Hi TS 1 Disable Hi TS 1 n a 212 F 1000 TS 2 Fail Disable LoTS 2 Disable LoTS 2 n a 14 F 10 C Hi TS 2 Disable Hi TS 2 n a 212 F 100 C Lo TS Filter 0 min Hi TS Filter n a 0 min Latch TS Alarms Yes CTL TS Fail Enable Other Alarms Configuration Sub Menu Parameter Factory User Lo Load Enable Lo Load 1 0A Lo Load Filter 0 sec Hi Load Disable Hi Load n a 30 0 A Hi Load Filter n a 0 sec Hi GFI Enable Hi GFI 50 mA Hi GFI Filter 0 sec Other Alarms Configuration Sub Menu Continued
59. a rating Ambi ent temperature conditions may affect load current ratings Caution Always be sure that the intended location is classified as an area that the product is approved for as defined by Article 500 of the National Electrical Code and or Part Section 18 of the Canadian Electrical Code 2 6 Mounting Procedures Mounting hole dimensions for the standard enclosures are shown in Appendix B on page 63 If possible conduit entries should be made in the bottom of the enclosure to reduce the possibility of water entry or leakage Conduit entries must be drilled punched following the enclosure man ufacturer s recommendations Use bushings suitable for the enclosure type and install such that the completed installation remains waterproof Grounding hubs and conductors must be installed in accordance with Article 501 4 b of the National Electrical Code and Part of the Canadian Electrical Code The user may want to consider enclosure drain holes in applications where moisture is a prob lem drill 0 125 holes in the bottom of the enclosure on both the left and right sides Two holes reduce the possibility that one will plug and ensures drainage if the enclosure is not perfectly level Note that drilling holes in the enclosure compromises the NEMA 4 rating Controllers should be removed from the enclosure before any holes are drilled or cut to prevent damage due to flying debris 2 6 1 CONTROL MODULE INSTALLATION AND REMOVAL Caution Alway
60. an isolated 920HTC 485 10260 004 1 2 wire RS 485 communication option installed DigiTrace 920 controller Control module with modem 920HTC MDM 10260 002 1 communications option installed Operator Console DigiTrace 920 controller Operator console 920CON 10260 005 1 Contact your local representative for other available configurations that are not listed above 11 Section 2 Installation and Wiring 2 1 Introduction 2 2 Initial Inspection 2 3 Operator Safety Considerations 2 4 Operating Environment 2 5 Installation Location Caution Be sure all personnel involved in installation servicing and programming are qualified and familiar with electrical equipment their ratings and proper practices and codes Multiple voltages and signal levels may be present during the installation operation and servicing of this product Do not power the product until the safety provisions outlined in this section have been observed This section includes information on the initial inspection preparation for use and storage instructions for the 920 series heat trace controller Caution Solid state relay SSR modules may be extremely hot immediately after power is removed Exercise care when handling SSRs Inspect the shipping container for damage If the shipping container or cushioning material is damaged it should be kept until the contents of the shipment have been verified for complete ness and the equipment has been checked
61. arm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e f the user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 10 HIGH VOLTAGE ALARM Purpose Alarms voltage levels that are higher than a preset limit for the application Serves as a monitor of the voltage used to power the trace circuit Alarm Mask ENABLE or DISABLE Range 10 to 330 volts VOLTAGE TURNS RATIO 1 00 Procedure Adjust the HIGH VOLTAGE ALARM level to the desired value The HIGH VOLTAGE ALARM must be enabled in order to adjust the HIGH VOLTAGE ALARM level Also the HIGH VOLTAGE ALARM level is affected by the VOLTAGE TURNS RATIO setting The absolute maximum adjusted HIGH VOLTAGE ALARM level is 1000 volts The absolute minimum adjusted HIGH VOLTAGE ALARM level is 1 volt See section 3 5 21 on page 26 for more information regarding the VOLTAGE TURNS RATIO function Note The HIGH VOLTAGE ALARM is only available if VOLTAGE SOURCE is set to the Point being used 37 38 amp 3 8 11 HIGH VOLTAGE ALARM FILTER TIME SETTING V3 11 AND UP Purpose The HIGH VOLTAGE ALARM FILTER will prevent HIGH VOLTAGE ALARMS from being indi cated until a high voltage condition has existed for the duration of t
62. ature will override the CONTROL SETPOINT temperature and force the controller output off if the TS 2 reading exceeds the HIGH TS 2 ALARM temperature setting This is a non latching condition so once the TS 2 reading drops below the HIGH TS 2 ALARM temperature setting the controller will resume normal operation Setting ENABLE or DISABLE Procedure Enable or disable the cutout feature as desired 4 Notes e The TS 2 HIGH LIMIT CUTOUT feature overrides an autocycle test A pending autocycle will be initiated immediately after the TS 2 temperature drops below the HIGH TS 2 ALARM tempera ture setting e IfaTS2 failure occurs and the TS 2 HIGH LIMIT CUTOUT feature is enabled the switch output will latch off regardless of the TS CONTROL MODE setting or the TS FAIL MODE setting 25 26 e fthe TS 2 HIGH LIMIT CUTOUT feature is enabled then the HIGH TS 2 ALARM temperature set ting can be set regardless of whether the HIGH TS 2 ALARM is enabled 3 5 19 VOLTAGE SOURCE V3 11 AND UP Purpose This parameter specifies which voltage source the HTC should use for its voltage mea surements Setting POINT A or POINT B or FIXED Procedure If the HTC is not powered from a dedicated switch interface an alternate voltage source can be selected If a fixed constant voltage value is to be used then that FIXED VOLTAGE SETTING must also be entered see section 3 5 20 on page 26 Notes e fan alternate voltage source is selected then all volta
63. ble or disable the cutout feature as desired ai Notes Ed e The TS 1 HIGH LIMIT CUTOUT feature overrides an autocycle test A pending autocycle will be initiated immediately after the TS 1 temperature drops below the HIGH TS 1 ALARM tempera ture setting e IfaTS1 failure occurs and the TS 1 HIGH LIMIT CUTOUT feature is enabled the switch output will latch off regardless of the TS CONTROL MODE setting or the TS FAIL MODE setting e fthe TS 1 HIGH LIMIT CUTOUT feature is enabled then the HIGH TS 1 ALARM temperature set ting can be set regardless of whether the HIGH TS 1 ALARM is enabled 3 5 16 TS 2 TYPE V3 11 AND UP Purpose This parameter specifies the type of RTD that is connected to the HTC s TS 2 input Setting 3 wire 100 Q platinum or 2 or 3 wire 100 9 nickel iron Ni Fe Procedure Select the type of RTD that is connected to the TS 2 input VA Note If a 2 wire 100 Q nickel iron Ni Fe RTD is selected then the TS 2 LEAD RESISTANCE must be entered see section 3 5 17 on page 25 3 5 17 TS 2 LEAD RESISTANCE V3 11 AND UP For Ni Fe RTDs only Purpose This parameter specifies the lead resistance of a 2 wire nickel iron RTD connected to the HTC s TS 2 input Range 0 to 20 00 Q Procedure Measure the resistance of one of the nickel iron RTD leads from the RTD to the HTC s TS 2 input and use this value as the TS 2 LEAD RESISTANCE 3 5 18 TS 2 HIGH LIMIT CUTOUT Purpose When enabled the TS 2 HIGH LIMIT CUTOUT fe
64. but lower than the current at worst case voltage The low current setting as a percentage of full load current will vary depending on the facility and its power system e A LOW CURRENT ALARM may also result from a switch failed open The controller cannot detect a switch failure due to no current A no current condition would be identified by a LOW CURRENT ALARM if enabled and the analog value reported with the alarm will be 0 0 A e t may be advantageous to consider using the HIGH RESISTANCE ALARM to indicate a cable fault when using certain types of heaters See sections 3 8 12 on page 38 and 3 8 14 on page 39 for an explanation of the resistance alarming feature 3 8 2 LOW LOAD CURRENT ALARM FILTER TIME SETTING V3 11 AND UP Purpose The LOW CURRENT ALARM FILTER will prevent LOW LOAD CURRENT ALARMS from being indicated until a low current condition has existed for the duration of the LOW CURRENT ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW CURRENT ALARM FILTER time to the desired value Note that the LOW CURRENT ALARM must be enabled in order to adjust the LOW CURRENT ALARM FILTER time Notes e Ifan alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e fthe user resets an alarm while the alarm condition is still exists the alarm w
65. configuration menu this sets the Point A MODBUS ADDRESS when in the Point B configuration menu this sets the Point B MOD BUS ADDRESS Either may be set independently of the other Range 1 to 247 Procedure Set the communications address as desired Together with the MODBUS SUB ADDRESS this combination must be unique to the entire communications network to avoid mes saging conflicts Either MODBUS protocol must be selected in order to set the MODBUS ADDRESS 3 9 4 MODBUS SUB ADDRESS V3 11 AND UP Purpose The MODBUS SUB ADDRESS along with the MODBUS ADDRESS defines the commu nications address to be used by the controller when using either MODBUS protocol to commu nicate with a MODBUS compatible device When in the Point A configuration menu this sets the Point A MODBUS SUB ADDRESS when in the Point B configuration menu this sets the Point B MODBUS SUB ADDRESS Either may be set independently of the other Range 0 to 31 Procedure Set the communications sub address as desired Together with the MODBUS ADDRESS this combination must be unique to the entire communications network to avoid mes saging conflicts Either MODBUS protocol must be selected in order to set the MODBUS SUB ADDRESS Note Since a 920 HTC does not use all 65 535 data addresses available for each MODBUS ADDRESS this data address range is subdivided to allow up to 32 HTCs to share the same MOD BUS ADDRESS This increas
66. d by the design 3 5 9 MAXIMUM POWER SETTING SSR ONLY Purpose This user selectable level limits the maximum amount of power applied to a heat trace circuit This is an average power calculated by the controller using the average current and applied voltage The HTC switches the output on and off rapidly to limit the average current to an appropriate level The MAXIMUM POWER level may be adjusted to eliminate step down transform ers lower the effective output wattage of a cable or implement energy management of the heat trace circuit Range 3 to 33 000 Watts VOLTAGE and CURRENT TURNS RATIOS 1 00 Procedure Adjust the MAXIMUM POWER level to the desired value watts Use the TEST TRACING function to observe the power limiting operation Notes This function may be set within reasonable limits for the particular tracer being powered The effective resolution of the setting is limited to 1 30th of the calculated full on power e Do not set the MAXIMUM POWER below full output for applications that do not require control of power This feature is affected by the VOLTAGE and CURRENT TURNS RATIO settings The maximum range using adjusted values of voltage and current is 65 535 watts See sections 3 5 21 on page 26 and 3 5 22 on page 26 for more information regarding the turns ratio functions 3 5 10 3 PHASE POWER CALCULATION V3 11 AND UP Purpose This parameter selects the type of power calculation that the HTC is to perform Set
67. d troubleshooting by providing a termination point for all of the low voltage signals The 920 control module may be installed or removed without dis turbing the field wiring Temperature sensor communications and alarm control wiring are con nected to the lever operated spring terminals providing gas tight vibration resistant connections 1 3 3 OPERATOR CONSOLE A large easy to read alphanumeric display and menu driven interface ease controller configura tion and eliminate the need for an external programmer The console may be left installed perma nently or may be installed temporarily for display setup during maintenance and troubleshooting Access is available for all monitored parameters programmed values and alarm information Enhanced security is provided by password protection The unique design of the operator console allows it to be installed or removed under power even in hazardous areas 1 3 4 SWITCH INTERFACE Universal single phase current monitoring single or 3 phase ground fault detection and volt age monitoring are provided by the Switch Interface SIS SIC module One device is required for each control point and two versions are available SIS for use with SSRs and SIC for use with the contactor Both units also incorporate a universal power supply allowing operation directly from 100 Vac to 277 Vac Use with higher trace voltages is also possible using a separate power source or a small step down transformer
68. ding to yield a load resistance in ohms If the controller s output switch is on but no current is present the RESISTANCE will read open circuit Note If the controller s output switch is off the RESISTANCE will display the last resistance which was calculated while the output switch was on 4 2 6 GROUND FAULT CURRENT Purpose If the controller detects any leakage current in the output circuit it will indicate the level in milliamps Note To minimize nuisance alarms the controller will not report a leakage current of less than 20 mAmps 4 2 7 VOLTAGE Purpose The voltage reading indicates the average circuit voltage being measured by the switch interface Note The controller calculates this parameter using the voltage sensed by the switch interface module and multiplying it by the VOLTAGE TURNS RATIO to yield an adjusted voltage value 4 2 8 POWER Purpose Load power provides an indication of the average power being consumed by the heat trace cable or the total 3 phase power being consumed by a balanced 3 phase star Y con nected load Notes The controller calculates load power by multiplying the average adjusted voltage reading by the average adjusted current reading e The controller may be set up to calculate total 3 phase power for a balanced star Y con nected load if the 3 PHASE POWER CALCULATION parameter is enabled In this case total 3 phase power is calculated using the following equation Pto
69. e Enable or disable the auto cycling feature as desired If the feature is disabled you will not be prompted to enter the AUTOCYCLE INTERVAL or AUTOCYCLE UNITS Notes e Auto cycling should always be enabled for normal operation Disabling this feature should only be required where the HTC system is monitoring a circuit exercised by some other device or means Although this function defeats temperature control and forces output on the controller will continue to adjust the output for protection purposes or power limiting SSR option only e Auto cycling is inhibited if the controller is in the load shedding mode See section 5 3 on page 52 e auto cycling is enabled the HTC will always autocycle for 10 seconds when power is ini tially applied e H auto cycling is enabled TS FAIL MODE OFF and all the control temperature sensors have failed the HTC will still perform an autocycle fan alarm condition with an alarm filter time greater than O appears during the auto cycling then the autocycle may be extended past the 10 seconds until the alarm filter time has expired 3 5 24 AUTOCYCLE TIME INTERVAL Purpose AUTOCYCLE INTERVAL is the number of hours minutes between successive heating cir cuit integrity tests depending on the AUTOCYCLE UNITS specified Range 1 to 240 Procedure Set the AUTOCYCLE INTERVAL to the desired time period Notes When using proportional ambient contactor mode the CYCLE TIME setting should be le
70. e Select the TEST TRACING function to force the output switch on for approximately 30 seconds After the test time has expired the unit will automatically revert to normal operation Notes e This feature only overrides temperature control it does not override other control parameters such as power limiting This feature is inhibited if the point is in load shedding mode 3 10 5 DISPLAY TEST V3 11 AND UP Purpose The DISPLAY TEST feature provides an easy method of illuminating each display seg ment and all the LEDs of the 920 Operator Console to ensure that they are functioning properly Procedure Select the DISPLAY TEST and watch the 920 console to verify that each display seg ment and each LED is illuminated during the test sequence Note Pressing any key on the 920 Operator Console keypad during the DISPLAY TEST causes the DISPLAY TEST to abort 3 11 Copy Configuration Functions V3 11 and up 46 The following functions provide a quick method of setting all of the controller s configuration parameters to a predefined state 3 11 1 COPY DEFAULTS TO COMMON V3 11 AND UP Purpose Loads Tyco Thermal Controls default configuration parameters that are common to both Point A and Point B as defined in Appendix F Procedure Enter the Copy Configuration Sub Menu and select DEFAULTS TO COMMON Notes This function overwrites the communication configuration parameters which could affect existing communications to the c
71. e EXTERNAL INPUT then the EXTERNAL INPUT must be set to TEMPBUS see Section 3 6 3 Also the CONTROL TS FAILURE ALARM is non latching in this mode Fail safe mode is always disabled if the TS CONTROL MODE EXT INPUT FAIL OFF ON 3 5 13 TS 1 TYPE V3 11 AND UP Purpose This parameter specifies the type of RTD that is connected to the HTC s TS 1 input Setting 3 wire 100 O platinum or 2 or 3 wire 100 9 nickel iron Ni Fe Procedure Select the type of RTD that is connected to the TS 1 input Note If a 2 wire 100 9 nickel iron Ni Fe RTD is selected then the TS 1 LEAD RESISTANCE must be entered manually see section 3 5 14 on page 24 3 5 14 TS 1 LEAD RESISTANCE V3 11 AND UP For Ni Fe RTDs only Purpose This parameter specifies the lead resistance of a 2 wire nickel iron RTD connected to the HTC s TS 1 input Range 0 to 20 00 Q Procedure Measure the resistance of one of the nickel iron RTD leads from the RTD to the HTC s TS 1 input and use this value as the TS 1 LEAD RESISTANCE 3 5 15 TS 1 HIGH LIMIT CUTOUT Purpose When enabled the TS 1 HIGH LIMIT GUTOUT feature will override the CONTROL SETPOINT temperature and force the controller output off if the TS 1 reading exceeds the HIGH TS 1 ALARM temperature setting This is a non latching condition so once the TS 1 reading drops below the HIGH TS 1 ALARM temperature setting the controller will resume normal operation Setting ENABLE or DISABLE Procedure Ena
72. e inactive if an INHIBIT override signal is being received 3 5 28 LOAD SHEDDING ENABLING Purpose The load shedding function allows the controller output to be forced OFF by way of a remote contact input on the 780 Group Communications Controller or using the communica tions port and an upstream device It may be used to turn OFF the output of one or more control lers in order to reduce energy consumption to avoid peak demand surcharges remove power from unused circuits or remove power from circuits that may be subjected to steam cleaning Setting ENABLE or DISABLE Procedure Enable or disable the load shedding control mode as desired Notes Tocompletely configure the HTC for load shedding operation the following additional param eters must be set up if using the Model 780 GCC 9000 Fail safe mode Load shedding GCC contact association These additional parameters may only be accessed using the Group Communications Con troller See the appropriate section of the GCC manual for further details Fail safe mode is not supported when using proportional ambient SSR mode or proportional ambient contactor mode e Fail safe mode is not supported if the TS CONTROL MODE EXT INPUT FAIL OFF ON Forfail safe mode to function at least one LOW TS ALARM of the controlling temperature sen sor s must be enabled and the corresponding LOW TS ALARM temperature setting must be less than the CONTROL SETPOINT temperature 3 6 Com
73. e trace is operated from the line to line connection eliminating the need for step down transformers or separate power sources This can be accomplished by removing the jumper between terminals 3 and 4 only Controller power can then be derived from the L1 trace power on terminals 1 and 2 and the incoming neutral con nection for controller power would be connected to terminal 4 Wiring diagrams for typical 1 and 2 pole configurations are included in Appendix C on page 68 Note The contactor version Switch Interface modules provide a switched line voltage signal to drive the contactor coil This is derived from the control power and as such requires that the contactor coil voltage be specified to match the control voltage present on terminals 2 and 4 Caution Many wiring configurations will use more than one power source and all must be de energized prior to performing any maintenance on a controller circuit When servicing one con trol point remember that power may also be present on the second control point Caution Before applying power to the controller ensure that powering the circuit will not dam age it if power limiting or the setpoint temperature have not been set correctly If there is any doubt the load should be disconnected until the 920 has been suitably programmed for correct and safe operation 17 2 9 Setup for the 920 2 8 1 INITIAL CABLE TEST To minimize the risk of damage to the controller due to a cable fault t
74. edding operation before the controller can be set up for load shedding control Three parameters must be set in the controller to configure it for load shedding operation 1 The load shedding feature must be enabled 2 The FAIL SAFE MODE parameter must be enabled or disabled depending on the application requirements If FAIL SAFE MODE is enabled then at least one LOW TS ALARM of a TS used in the TS CONTROL MODE must be enabled If the alarm temperature exceeds the CONTROL SET POINT temperature fail safe mode will be disabled 3 The GCC contact input s or zone definition bits of an external communicating device that are to be associated with the load shedding action for the controller must be defined These parameters can only be configured using an external communicating device or the Model 780 GCC 9000 Group Communications Controller Refer to the Model 780 GCC 9000 user man ual for details on how to set up these options The optional 920 Operator Console can be used to enable or disable the load shedding feature but not to set any other load shedding parameters Notes e Fail safe mode is always disabled if the SWITCH CONTROL MODE is set to either of the two pro portional ambient control modes or the TS CONTROL MODE EXT INPUT FAIL OFF ON e Fail safe mode is disabled if the TS CONTROL MODE is set to either EXT INPUT FAIL TS 1 or EXT INPUT FAIL TS 2 and a control temperature failure occurs The HTC will turn on its output swi
75. emperature the output will have a duty cycle of 096 The controller output will be off for 1 30th of the CYCLE TIME setting before the duty cycle is calculated again Proportional Ambient Contactor Control Temperature Band Control Sensor Temperature Duty Cycle Setpoint 0 Setpoint proportional band 2 50 Setpoint proportional band 100 Note The load shedding fail safe mode is not supported when using proportional ambient con tactor control since ambient temperature is being monitored rather than pipe temperature Ifan AC alarm with an alarm filter time greater than 0 is detected the contactor will not toggle until the alarm filter time has expired 5 3 Load Shedding Control Mode 52 Load shedding is a control mode that can be programmed and initiated only by an external com municating device or by the Model 780 GCC 9000 Group Communications Controller which overrides temperature control and forces the output of the controller OFF until reset by the 780 GCC When using a GCC load shedding is initiated by a contact closure or opening on one of the four contact inputs Each contact input initiates a load shedding command for the group of 5 4 TEMPBUS Control Mode controllers associated with that contact input Each controller may be associated with one or more groups Refer to the Load Shedding Section in the GCC manual for details on setting up the load shedding features of the HTC when using a GCC When power i
76. enu else a PROPORTIONAL BAND setting will be available No MAXIMUM POWER SWITCH CUR RENT RATING or CIRCUIT BREAKER CURRENT RATING settings are available when the controller is set to operate in either contactor mode If proportional ambient contactor is selected the CYCLE TIME setting will also be available 3 5 4 PROPORTIONAL BAND SETTING For use with the three proportional control modes only Purpose When an HTC equipped with SSRs is used to control a heating circuit proportional or proportional ambient SSR modes are normally used allowing for more precise temperature con trol When using contactors the proportional ambient contactor mode should be selected This programmable proportional band acts to vary the on to off time of the output based on the difference between the measured control temperature and the desired CONTROL SETPOINT temperature Range 2 F to 90 F 1 C to 50 C 2 F to 630 F 1 C to 350 C V3 2x and up Procedure Adjust the PROPORTIONAL BAND setting to the desired differential from the CONTROL SETPOINT temperature Notes See section 5 2 on page 50 for an explanation of how the three proportional modes use the PROPORTIONAL BAND setting When using series type constant wattage or self regulating tracers in an ambient tempera ture control application significant energy savings may be realized by setting the PROPOR TIONAL BAND to match the expected range of operating ambient temperatures Tracer de
77. er RTD 2 Sense 11 O Common 12 c Terminal board Shield Control Point B Source RTD 1 Control Point B RTD 2 Control Point B TS1 and TS2 wiring diagram Sense L Common Shield Source Sense n 13 Drain 149 Jumper 15 100 Q0 Ni Fe RTD 100 Q0 Ni Fe RTD 100 Q Ni Fe RTD 100 Q Ni Fe RTD 69 C 2 Power Wiring C 2 1 CONTROLLER POWERED DIRECTLY FROM 1 PH OR 3 WIRE 3 PH SOURCE Trace power in L1 line D l L line Control power in L1 line L a 1PH or 3 wire 3PH Trace power in L2 neutral AI L2 neutral Input power Control power in L2 neutral J2 L Max 277 Vac line line Trace power in L3 25 L3 Trace power out L1 line d 6 L1 line Trace power out L2 neutral d 7 L2 neutral NA past race power out L3 8 L3 e W 4 Notes 1 Jumpers 1 and J2 are normally supplied by the Factory 2 Terminals 5 and 8 are only supplied when 3 phase versions are ordered from the Factory C 2 2 CONTROLLER POWERED DIRECTLY FROM 4 WIRE 3 PH SOURCE S Trace power in L1 line ol LI Control power in L1 line Lo 4 wire 3PH Trace power in L2 neutral 3 Input power Control power in L2 neutral 34 Neutral Max 277 Vac line neutral Trace power in L3 5 L3 Trace power out L1 line Bf L1 Ww Trace power out L2 neutral 7 10 Trace power out L3 a L3 Aw Tracer s o WM Notes 1
78. er to the wiring diagrams in Appendix C on page 68 for example connection details Alarm and Control Signals Terminal No Alarm relay dry contact output 17 Alarm relay dry contact output 18 Ground 19 9 Vdc nominal Out 100 mAmps maximum 1 Common 2 Common 3 2 7 3 EXTERNAL INPUT OUTPUT These input and output terminals are used to implement the Override and Ambient Temperature Control Mode features Refer to Section 3 on page 18 for programming details and Appendix C on page 68 for example wiring diagrams Miscellaneous Signals Terminal No External input 20 External input 21 External output 4 External output 2 7 4 COMMUNICATION SIGNAL CONNECTIONS The communications terminal assignments change based on the type of option installed If present in a control module the type of communications interface will be identified by a label located next to the module s rating label Communications wiring should use twisted conductor shielded cable Shields on communica tions wiring should be grounded at one end only using the terminals provided The following tables define the appropriate signal connections for the various types of interfaces RS 485 2 Wire Connections Communication Signal Terminal No Receive transmit data 6 Receive transmit data 22 Shield 8 Shield 24 RS 232 Connections Communication Signal Terminal No Recei
79. es the number of HTCs allowed on a single MODBUS port from 247 to 7 904 2247 x 32 This requires that any HTC sharing the same MODBUS ADDRESS as another HTC must have its own unique MODBUS SUB ADDRESS 43 44 amp 3 9 5 BAUD RATE Purpose Defines the data rate at which communications occur Setting AUTO or 9600 or 4800 or 2400 or 1200 or 600 or 300 Procedure Select the data rate to be compatible with other devices that will be connected to the controller for communications purposes Note Not all communications interfaces support the various data rates so the data rate should be set to AUTO The controller will automatically select a BAUD RATE that is compatible with the communications interface installed If BAUD RATE AUTO and a MODEM communication interface is used a data rate of 300 is selected Otherwise if BAUD RATE AUTO and a non MODEM com munications interface is used a data rate of 9600 is used 3 9 6 PARITY MODBUS V3 11 AND UP Purpose Defines the type of parity bit used with MODBUS communications Setting NONE or ODD or EVEN Procedure Select the desired type of parity Note that PARITY can only be selected when using either MODBUS protocol 3 9 7 HARDWARE Purpose Identifies the type of communications interface installed in the 920 control module The controller automatically determines and displays which communications interface type is available Values NONE MODEM or 232
80. f 920 hardware A 0 indicates that an EPROM is being used which means the firmware cannot be upgraded without replacing the EPROM A 1 indicates that the firmware is stored in a FLASH memory device and can be upgraded via the optional communications interface 3 6 3 EXTERNAL INPUT PORT Purpose This input port may be used as an OVERRIDE SOURCE or a TEMPBUS temperature source for either point As an OVERRIDE SOURCE it can sense a remote dry contact closure and 29 30 amp override the controller s temperature control and force its output switch off or on As a TEMPBUS M temperature source either controller can control its output switch using the TEMPBUS temper ature rather than temperatures from TS 1 or TS 2 Setting NOT USED TEMPBUS V3 11 INHIBIT or FORCE ON V3 11 Procedure If the EXTERNAL INPUT is not being used by either point select NOT USED If either point requires a TEMPBUS temperature signal select TEMPBUS and set the point TS CONTROL MODE to a mode using the EXTERNAL INPUT see section 3 5 12 on page 24 For TEMPBUS operation description see section 5 4 on page 53 If a remote dry contact closure should force either point s output switch off select INHIBIT If a remote dry contact closure should force either point s output switch on select FORCE ON If the EXTERNAL INPUT is set to INHIBIT or FORCE ON the point s OVERRIDE SOURCE for V3 11 must be set to EXT INPUT or its INHIBIT CO
81. for future design criteria The value of this accumulator is written to the controller s nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user Procedure The POWER ACCUMULATOR may be reset to zero using the optional 920 Operator Console V3 11 or a communicating device Note The POWER ACCUMULATOR value will roll over to zero when the upper limit of the POWER ACCUMULATOR has been exceeded This upper limit is 429 496 729 5 kW hours for V3 00 and 214 748 364 7 kW hours for V3 11 and up 4 3 3 CONTACTOR CYCLE COUNTER V3 11 AND UP Purpose This feature indicates the total number of off to on transitions a contactor has com pleted since the last time the CONTACTOR CYCLE COUNTER was reset This serves as a method to do preventative maintenance on the contactor according to the manufacturer s specifications The count value is written to the controller s nonvolatile memory once every 24 hours or when ever any maintenance data is reset by the user Procedure The CONTACTOR CYCLE COUNTER may be reset to zero using the optional 920 Opera tor Console or a communicating device Notes Once the CONTACTOR CYCLE COUNTER reaches 999 999 999 it stops counting The CONTACTOR CYCLE COUNTER is only indicated if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR 4 3 4 TIME IN USE Purpose The purpose of this feature is to indicate the total hours of controller use since its
82. ge alarming features are disabled for this HTC and the VOLTAGE TURNS RATIO is not used e Itis not possible to set both points to use the others voltage source 3 5 20 FIXED VOLTAGE SETTING V3 11 AND UP Only if VOLTAGE SOURCE FIXED Purpose This parameter specifies the voltage value that the HTC should use when the VOLTAGE SOURCE FIXED Range 0 to 1000 Volts Procedure Adjust the FIXED VOLTAGE setting to the desired level Note All voltage alarming features are disabled for this HTC and the VOLTAGE TURNS RATIO is not used when the VOLTAGE SOURCE is set to FIXED 3 5 21 VOLTAGE TURNS RATIO ADJUSTMENT Purpose The VOLTAGE TURNS RATIO adjusts voltage readings for applications where a controller is switching a load through a step up or step down transformer or is being powered from a source with a different voltage level than the trace voltage Range 0 10 to 9 90 TO 1 Procedure Adjust the VOLTAGE TURNS RATIO to equal the ratio of the circuit voltage to the con troller input voltage Compare the indicated voltage to the measured voltage after setting the turns ratio and adjust until the two readings are as close as possible e g Heating Circuit Voltage 480 Volts Module Input Voltage 120 Volts VOLTAGE TURNS RATIO Setting 4 00 Notes e When the VOLTAGE TURNS RATIO has been set appropriately the HTC will calculate the circuit power using the adjusted current and voltage readings Voltage alarms also use the adj
83. he HIGH VOLTAGE ALARM FIL TER time Range 0 to 12 seconds Procedure Adjust the HIGH VOLTAGE ALARM FILTER time to the desired value The HIGH VOLTAGE ALARM must be enabled to adjust the HIGH VOLTAGE ALARM FILTER time Also the HIGH VOLTAGE ALARM FILTER is only available if VOLTAGE SOURCE is set to the Point being used Notes e Ifan alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated fthe user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 12 LOW RESISTANCE ALARM Purpose Alarms heater resistance levels that have decreased from the NOMINAL RESISTANCE setting by more than the selected amount Alarm Mask ENABLE or DISABLE Range 1 to 100 deviation from NOMINAL RESISTANCE Procedure Adjust the LOW RESISTANCE ALARM deviation to the desired value The LOW RESIS TANCE ALARM must be enabled in order to adjust the LOW RESISTANCE deviation Notes This feature is not normally enabled It can be used effectively to guard against accidental paralleling of heating circuits Be careful when using this alarm feature with heating cables that exhibit a variable resistance with temperature Low resistance alarming may not be prac tical when the load has an
84. he integrity of the heating cable should be verified by 1 Using a megger to perform a high voltage insulation test 2 Using an ohmmeter to ensure that the heating cable is not shorted These tests must be performed with the controller output disconnected Once the cable has been checked it may be reconnected to the controller and power applied 2 8 2 RANDOM START DELAY All 920 series control modules incorporate a RANDOM START UP DELAY feature ensuring that all units do not power on at the same time When power is first applied to a controller it will hold its output off for a random time 0 to 9 seconds equal to the last digit of the HTCBUS communi cations address see section 3 9 2 on page 43 Once the start up delay has timed out the con troller will begin normal operation The 920 may be programmed using the optional 920 Operator Console or a Group Communica tions Controller GCC if the modem communications option is installed For instructions on the operation of these devices refer to the corresponding operating manuals For complete instruc tions on programming the 920 see the Section 3 on page 18 2 9 1 VOLTAGE READING SETUP The 920 series control module is tested calibrated and ordered separately from the switch interface modules which contain the voltage sensing circuitry This prevents Tyco Thermal Controls from calibrating the control modules to specific switch interfaces and removing any component inaccuracies
85. icates that the controller has detected a failure in its nonvolatile memory Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming of a nonvolatile memory failure as desired Note The EEROM DATA FAILURE ALARM should always be enabled This memory stores all of the controller s configuration and calibration settings and the alarm will only be generated if the microprocessor cannot bypass the failed area of its memory This indicates an internal problem and the control module should be replaced and returned to Tyco Thermal Controls for repair The following section describes the setup parameters that relate to the way the controller com municates with another device If the optional communications interface is not installed in the 920 control module these parameters need not be configured All these parameters are com mon for both of the two control points Point A and Point B except the HTCBUS ADDRESS MODBUS ADDRESS and MODBUS SUB ADDRESS settings as applicable 3 9 1 PROTOCOL Purpose Defines the communications language used by the controller to communicate with other devices Setting HTCBUS or MODBUS ASCII V3 11 or MODBUS RTU V3 11 Procedure Select the HTCBUS protocol when communicating with existing Tyco Thermal Con trols Heat Trace Control products including the Model 780 GCC 9000 Group Communications Controller If you are communicating directly with the controller using a different device se
86. ies switch interface detects ground faults by summing the outgoing and return trace currents through an internal current transformer Under normal operating conditions no ground fault condition this current will be zero When there is a flow of current from one of the trace supply wires to ground a ground fault condition occurs If a ground fault alarm is present on start up of a new installation it is likely due to a wiring error or damaged cable To verify this condition Check that the heating circuit neutrals return to the controller and are not connected directly to the distribution panel This can be a common problem if the installation is a retrofit situa tion On paralleled circuits be certain that ALL neutrals return The late addition of a circuit may not be obvious Use the monitoring feature available at the 920 Operator Console or the Model 780 GCC 9000 Group Communications Controller to view the measured ground fault current at the heat trace controller If this value is at the maximum that the controller can measure it is usually an indication that the wiring is incorrect If the value is less than 250 mAmps an actual ground fault condition may exist in the cable V4 Note The controller monitors the integrity of the ground fault GF detection transformer and associated wiring If a fault is detected the controller will report a GF value of 300 mAmps 57 6 3 Common Alarms What to look for Alarm Descriptio
87. if the corresponding HIGH LIMIT CUTOUT has been enabled ENA This Section describes the setup parameters that relate to a specific control point either Point A or Point B These parameters must be configured for each of the two control points that are used 3 5 1 CONTROL SETPOINT TEMPERATURE Purpose The CONTROL SETPOINT temperature is the value at which the heat trace controller maintains the circuit temperature through either proportional proportional ambient SSR propor tional ambient contactor or deadband control depending on the controllers configuration The CONTROL SETPOINT temperature is compared to the temperature measured by the control tem perature sensor TS A decision is then made to turn on or turn off the output to control power to the tracer Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the CONTROL SETPOINT temperature value to the desired maintain tempera ture The HTC will switch the output ON and OFF in an attempt to maintain this temperature Notes See section 5 2 on page 50 of this manual for an explanation of Proportional Proportional Ambient SSR Proportional Ambient Contactor and Deadband Control algorithms e When using an optional 920 Operator Console for V3 11 and up the CONTROL SETPOINT temperature range may be limited to the CONSOLE SETPOINT MAXIMUM and MINIMUM values see sections 3 5 29 on page 29 and 3 5 30 on page 29 This is a safety feature to prevent users in the field f
88. ile the controller is pow ered even in Class Division 2 and Zone 2 hazardous areas lt may be temporarily or perma nently installed The console is installed in three steps Step Hook the lip provided on the rear cover of the console over the top edge of the con trol module front plate Fig 2 2 Console installation Step 1 Step Hinge the bottom of the console downwards until it is flush with the front of the con trol module Fig 2 3 Console installation Step 2 Step El If the console is to be permanently installed secure it to the control module using the captive screw provided It should be finger tight only Do not over tighten the screw or damage to the console housing may occur Fig 2 4 Console installation Step 3 To remove the console follow the three steps outlined above in reverse order 2 7 Wiring Wiring diagrams for typical configurations are included in Appendix C on page 68 Caution Always verify wiring connections before applying power to the controller or connected circuits To avoid injury or equipment damage do not install or remove wiring while controller power is on To minimize the chance of loose connections the terminal board uses lever operated spring loaded terminals See Appendix A on page 61 for allowable wire sizes and recommended insula tion strip lengths F Note Some RTDs may be constructed with the Sense wire color coded as Black KA 2 7 1 TEMPERA
89. ill not be indi cated again until the entire alarm filter time has expired 3 8 3 HIGH LOAD CURRENT ALARM Purpose Alarms current levels that are higher than a preset limit for the application Alarm Mask ENABLE or DISABLE Range 0 3 to 100 0 amps CURRENT TURNS RATIO 1 00 Procedure Adjust the HIGH CURRENT ALARM level to the desired value Note that the HIGH CUR RENT ALARM must be enabled in order to adjust the HIGH CURRENT ALARM level Also note that the HIGH CURRENT ALARM level is affected by the CURRENT TURNS RATIO setting The absolute maximum adjusted HIGH CURRENT ALARM level is 300 0 amps The absolute minimum adjusted 35 36 HIGH CURRENT ALARM level is 0 1 amps See section 3 5 22 on page 26 for more information regarding the CURRENT TURNS RATIO function Note As the HTC automatically protects itself from overload it would not normally be necessary to enable this alarm This automatic protection can be used effectively to guard against acciden tal paralleling of heating circuits In rush or cold start currents typically associated with self regulating cables may cause nuisance HIGH CURRENT ALARMS If this is undesirable the alarm should be disabled 3 8 4 HIGH LOAD CURRENT ALARM FILTER TIME SETTING V3 11 AND UP Purpose The HIGH CURRENT ALARM FILTER will prevent HIGH LOAD CURRENT ALARMS from being indicated until a high current condition has existed for the duration of the HIGH CURRENT ALARM FILTER time Range
90. increasing resistance with temperature such as self regulating cables Use of the LOW RESISTANCE ALARM assumes that the controller power is derived from the same circuit as the tracing power either by direct connection or through a step down trans former Disable this alarm if the controller is powered from a separate circuit No LOW RESISTANCE ALARMS will be generated if the measured voltage is below the LOW VOLTAGE ALARM setpoint regardless of whether the LOW VOLTAGE ALARM is enabled This stops an alarm from being generated when the circuit power is turned off If the LOW VOLTAGE ALARM is disabled ensure that the LOW VOLTAGE setpoint is set to a relevant level otherwise no LOW RESISTANCE ALARMS will occur e LOW RESISTANCE ALARMS will only be generated if the output switch is on 3 8 13 LOW RESISTANCE ALARM FILTER TIME SETTING V3 11 AND UP Purpose The LOW RESISTANCE ALARM FILTER will prevent LOW RESISTANCE ALARMS from being indicated until a low resistance condition has existed for the duration of the LOW RESISTANCE ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW RESISTANCE ALARM FILTER time to the desired value The LOW RESISTANCE ALARM must be enabled to adjust the LOW RESISTANCE ALARM FILTER time Notes e Ifan alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the
91. ini tial operation It may be useful to log the amount of time a controller has been in service for the purposes of maintenance planning or reliability testing The value of this accumulator is written to the controller s nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user Procedure The IN USE hours accumulator can be reset to zero using the optional 920 Operator Console V3 11 or a communicating device 49 MA 2 Section 5 Control Modes 5 1 Introduction 5 2 Switch Control Modes 50 Note The IN USE hours accumulator value will roll over to zero when the upper limit of the accu mulator has been exceeded This limit is 4 294 967 295 hours for V3 00 and 999 999 999 hours for V3 11 and up 4 3 5 TIME SINCE LAST RESET Purpose This feature indicates the total hours of controller use since the last reset It may be useful to log the amount of time a particular controller has been in service since the last time the controller s power was cycled for troubleshooting purposes Procedure The TIME SINCE LAST RESET hours accumulator can only be reset by cycling the con troller s power Note The TIME SINCE LAST RESET will roll over to zero when the upper limit of 65 535 hours has been exceeded 4 3 6 PEAK LOAD CURRENT V3 11 AND UP Note The PEAK LOAD CURRENT is not displayed on the optional 920 Operator Console Purpose This feature indicates the highest instantaneous load current
92. ired Note This selectable TX DELAY is only used if the PROFILE is set to either RS 485 or AUTO and an RS 485 interface is installed The following features are part of the controller s programming but are only used in conjunction with the optional 920 Operator Console For a detailed description of each of the console fea tures and operating instructions refer to the separate document DigiTrace 920 Series HTC Oper ator Console Installation and Operating Instructions Tyco Thermal Controls reference H56903 for the particular version of controller firmware that you are using 3 10 1 PASSCODE Purpose The four digit PASSCODE feature prevents unauthorized users from modifying the con troller s configuration parameters via a 920 Operator Console Range 0000 to 9999 Procedure Enter the desired PASSCODE in the Common Setup sub menu using the optional 920 Operator Console keypad A PASSCODE of 0000 disables the lockout feature and allows all configuration parameters to be modified using the 920 Operator Console without requiring a PASSCODE Setting the PASSCODE to any other value will require the database to be unlocked by entering the correct PASSCODE prior to modifying any of the controller s configuration parame ters using the optional 920 Operator Console Note The PASSCODE can only be edited if it is set to 0 or the database has been unlocked by entering the proper PASSCODE 3 10 2 LOCK DATABASE Purpose If the PASSCODE ha
93. is copied the last character incremented by one and then written to Point B s TAG None of the communications addresses or the maintenance data values are copied 3 11 5 COPY POINT B TO POINT A V3 11 AND UP Purpose Copies the point specific configuration parameters of Point B to Point A Point B s con figuration parameters are not changed Procedure Enter the Copy Configuration Sub Menu and select B TO A VA Notes e To ensure that the TAGs for both points are not the same Point B s TAG is copied the last character incremented by one and then written to Point A s TAG None of the communications addresses or the maintenance data values are copied Section 4 Monitored Parameters 4 1 Introduction The following is a brief summary of each of the measured and calculated parameters the 920 series control module provides to the user Detailed information regarding settings alarms lim its etc may be found in Section 3 on page 18 For detailed information regarding the display of these variables using the 920 operator console or the Model 780 GCC 9000 refer to the appro priate user manuals 4 2 Analog Readings 4 2 1 CONTROL TEMPERATURE Purpose This is the temperature the controller uses to determine whether its output switch should be on or off Depending on the TS CONTROL MODE setting whether one or two RTDs are installed and TEMPBUS is being used the CONTROL TEMPERATURE may be derived from TS 1 TS 2 TEMPBUS
94. ith window and quick release latches control module and oper ator console Includes an isolated 2 wire RS 485 communication option 1P 30 A 277 V SSR pt Controls two circuits each with a 1 pole solid state relay Approved for Class 1 Div 2 areas DigiTrace 920 controller 2 Pt in a 14 x 12 x 8 FRP enclosure 920 E4FWL SIS302 883202 HTC CON 10160 012 32 with window and quick release latches control module and oper ator console 2P 30 A 277 V SSR pt Controls two circuits each with a 2 pole solid state relay Approved for Class 1 Div 2 areas DigiTrace 920 controller 2 Pt in a 14 x 12 x 8 FRP enclosure 920 E4FWL S18302 883202 HTC485 CON 10160 013 32 with window and quick release latches control module and oper ator console Includes an isolated 2 wire RS 485 communication option 2P 30 A 277 V SSR pt Controls two circuits each with a 2 pole solid state relay Approved for Class 1 Div 2 areas DigiTrace DigiTrace Supervisory Software DigiTrace Supervisor 10391 002 1 Note The NEC and CEC rules specify that all ungrounded i e hot legs of a circuit must be switched in the event of a ground fault This means for 207 V single phase applications you must specify a 2 pole 2P version if you are not using external GFI breakers Control Modules DigiTrace 920 controller Control module only 920HTC 10260 001 1 No communications options installed DigiTrace 920 controller Control module with
95. lect the MODBUS protocol For a detailed description of the controller s MODBUS mapping please refer to the sep arate DigiTrace 920 Series Heat Trace Controller Modbus Protocol Interface Mapping docu ment Tyco Thermal Controls reference H57366 3 9 2 HTCBUS ADDRESS Purpose Defines the communications address to be used by the controller when using the HTC BUS protocol to communicate with a Model 780 GCC 9000 When in the Point A configuration menu this sets the Point A HTCBUS ADDRESS when in the Point B configuration menu this sets the Point B HTCBUS ADDRESS Either may be set independently of the other Range 1 to 16 777 215 Procedure Set the communications address as desired This must be an address unique to the entire communications network to avoid messaging conflicts The HTCBUS protocol must be selected in order to set the HTCBUS ADDRESS Note A unique HTCBUS communications address is always assigned by Tyco Thermal Controls and identified by the label on the front of the 920 control module see Figure 3 1 Use the preas signed address whenever possible to minimize the chances of an address being duplicated in the user s system 3 9 3 MODBUS ADDRESS V3 11 AND UP Purpose The MODBUS ADDRESS along with the MODBUS SUB ADDRESS defines the commu nications address to be used by the controller when using either MODBUS protocol to commu nicate with a MODBUS compatible device When in the Point A
96. ller and how they can be accessed The first line of each section identifies the function to be described Each section goes on to explain the Purpose of the function the Range over which it may be set the Procedure for setting or enabling the feature and finally any Notes or Cautions that pertain to the particular function Setting and using the alarming functions of the 920 controller is a two step procedure 1 The alarm must be enabled or disabled accordingly When using the 920 Operator Console access to all alarming functions is available using the CONFIGURE mode sub menus When using the Model 780 GCC 9000 Group Communications Controller the alarm masks may be found in the HTC SETUP Section Please see the appropriate operating manual for instructions on accessing these parameters 2 The corresponding alarm point value may be modified appropriately for the application When using the 920 Operator Console access to the alarm points is also available using the CONFIGURE mode sub menus Modification of the alarm setpoint values is found in the HTC SETPOINTS Section of the Model 780 GCC 9000 Group Communications Controller Please see the appropriate operating manual for instructions on accessing this feature Note The 920 Operator Console or the Model 780 GCC 9000 will not allow modification of an alarm point value if the alarm has been disabled DIS with the exception of the HIGH TS ALARM temperature settings These may still be modified
97. ly Each of the three lead wires must be of the same gauge The ideal installation has a separate conduit for the RTD leads if they have been extended It is not usually a problem to run low signal levels in the same conduit as the power leads even in high power applications as long as the RTD wire is a twisted shielded type with an insula tion rating equal to or greater than the highest voltage in the conduit Follow the proper Elec trical Code for your particular installation Terminal connections that are not tight can add resistance to an RTD circuit Check the tight ness of all screw terminal connections at time of installation and during subsequent mainte nance checks e Check the specifications for the particular cable being used to ensure that it does not have excessive capacitance when used in long lengths This can cause a temperature offset between what the controller reads and what the RTD actually measures This again is nor mally not a problem since the controller compensates for all but the worst cases of this Lastly itis possible for the RTD itself to fail on an intermittent basis but this failure mode should be considered unusual This kind of failure is probably the most difficult to find but fortunately it is also the least likely as a failure mechanism 6 2 3 GROUND FAULT Ground fault alarms can be due to incorrect installation as well as leakage resulting from wet system components or faulted cables The 920 ser
98. mon Controller Setup 3 5 29 CONSOLE SETPOINT MAXIMUM V3 11 AND UP Note The CONSOLE SETPOINT MAXIMUM is not displayed on the optional 920 Operator Console Purpose When using an optional 920 Operator Console for V3 11 and up the maximum set ting of the CONTROL SETPOINT temperature may be limited to the CONSOLE SETPOINT MAXIMUM value This is a safety feature to prevent users in the field from modifying the CONTROL SETPOINT temperature setting to a dangerous level Range 76 F to 1058 60 C to 570 C Procedure Adjust the CONSOLE SETPOINT MAXIMUM temperature value to limit the maximum allowable CONTROL SETPOINT TEMPERATURE that may be set using the optional 920 Operator Console The CONSOLE SETPOINT MAXIMUM may only be set using a communicating device such as the Model 780 GCC 9000 See the 780 GCC 9000 manual for the proper procedure 3 5 30 CONSOLE SETPOINT MINIMUM V3 11 AND UP Note The CONSOLE SETPOINT MINIMUM is not displayed on the optional 920 Operator Console Purpose When using an optional 920 Operator Console for V3 11 and up the minimum setting of the CONTROL SETPOINT temperature may be limited to the CONSOLE SETPOINT MINIMUM value This is a safety feature to prevent users in the field from modifying the CONTROL SETPOINT tem perature setting to a dangerous level Range 76 F to 1058 60 C to 570 C Procedure Adjust the CONSOLE SETPOINT MINIMUM temperature value to limit the minimum allowable CONTROL SETPO
99. ms for one control point with the second control point When programming or troubleshooting a ways confirm that you are referencing the control point of interest either Point A or Point B 6 2 2 RTDS RTD failures after installation can generally be attributed to incorrect wiring or improper installa tion of the sensor Some specific RTD problems and troubleshooting methods follow 1 TS Failure Alarm s If the HTC controller indicates a failure of an RTD Ensure that the RTD is a 3 wire 100 9 Platinum Type for V3 00 For V3 11 and up ensure that the TS TYPE setting matches the RTD being used e Turn off the power to the controller before proceeding e Disconnect the RTD wiring from the input terminals Measure the RTD s resistance between the source WHT and sense WHT leads at the con troller It should not exceed 40 Q Excessive lead resistance will cause a TS FAILURE ALARM and must be corrected Look for loose terminals excessive lead length or insufficient wire gauge and correct as necessary Measure the RTD s resistance between the source WHT or sense WHT lead and the com mon RED lead of the RTD at the controller This should be between 60 Q and 330 Q depend 55 56 ing on the temperature and the lead resistance See Appendix D on page 74 or Appendix E on page 75 Verify that the RTD is wired correctly The heat tracing controllers will always be terminated in the order source WHT sense WHT common R
100. n Cause of Alarm High TS 1 TS 2 Temperature Appears when the temperature exceeds the HIGH TS Alarm temperature setting too close to maintain ALARM temperature e Flow of hot product Steaming out lines Incorrect tracer wiring Incorrect RTD TYPE selected Low TS 1 TS 2 Temperature Appears when the temperature decreases below the Alarm temperature setting too close to maintain LOW TS ALARM temperature temperature e Flow of cold product Empty pipe Damaged wet or missing insulation Heating cable not sized properly for the application Heating cable damaged Incorrect RTD TYPE selected TS 1 TS 2 Failure Indicates that a sensor is operating improperly ncorrect or damaged field wiring open leads or excess resistance either intermittent or continuous may be due to broken or damaged wires or loose terminals Damaged or inoperative temperature sensors Control TS Failure Alarms a failure of the temperature sensing element designated as the control element by the TS CONTROL MODE setting Depending on the chosen TS FAIL MODE and TS CONTROL MODE the output switch may be latched off or on until this failure is corrected Incorrect or damaged field wiring open leads or excess resistance either intermittent or continuous may be due to broken or damaged wires or loose terminals Damaged or inoperative temperature sensors High Current Alarms current levels that are greater than the HIGH CURRENT
101. n an HTC equipped with a contactor is used to control a trace circuit it is neces sary to use deadband rather than proportional control This is done to prevent the contactor from switching on and off rapidly and being worn out prematurely This deadband acts as an on off control where the decision to turn the output off or on is based upon a window of difference between the measured control temperature and the desired CONTROL SETPOINT temperature Range 2 F to 90 F 1 C to 50 C Procedure Adjust the DEADBAND setting to the desired differential from the desired CONTROL SETPOINT temperature When the control temperature is above the setpoint deadband value the controller will turn off the output to the tracer If the control temperature drops down below the setpoint the output will be turned back on Note that the smaller the DEADBAND setting the more often the contactor will cycle on and off decreasing its operational life Notes See section 5 2 on page 50 for an explanation of deadband control Note that the MAXIMUM POWER SWITCH CURRENT RATING and CIRCUIT BREAKER CURRENT RATING settings are not available when the HTC is set to deadband mode typically when switching a contactor The DEADBAND parameter is also available for Point A when the EXTERNAL OUTPUT is config ured for use as an INHIBIT output See section 3 6 4 on page 30 for additional details 3 5 6 CYCLE TIME SETTING V3 11 AND UP For proportional ambient contact
102. nd an RS 232 communication interface is used with 920 V3 00 e 3 WIRE RS 232 Continuously asserts RTS CTS and DCD are ignored This is the profile used when PROFILE AUTO and an RS 232 communication interface is used with 920 V3 11 e RS 485 Uses RTS and the Tx Delay timer CTS and DCD are ignored This is the profile used when PROFILE AUTO and an RS 485 communication interface is used EXTERNAL MODEM Uses RTS and the Tx Delay timer ignores CTS uses DCD to qualify each receive data character and to sense an idle channel condition e 1200 BAUD MODEM Uses RTS with a fixed 10 msec Tx Delay time ignores CTS uses DCD to qualify each receive data character This is the profile used when PROFILE AUTO BAUD RATE 1200 and a MODEM communication interface is used e 300 BAUD MODEM Uses RTS with a fixed 30 msec Tx Delay time ignores CTS uses DCD to qualify each receive data character This is the profile used when PROFILE AUTO BAUD RATE 1200 and a MODEM communication interface is used 3 9 10 TX DELAY Purpose Allows a programmable delay between the receipt of a communications message and the controller s reply In some applications it may be necessary to delay the controller s response to an inquiry for a short period of time to allow external devices to start up stabilize and or synchronize Range 0 00 to 2 50 seconds Procedure Set the amount of delay between the receipt of a message and the controller s response as requ
103. nd mode or the proportional ambient contactor mode Switching device failure alarms are supported for both types of output devices Ground Fault Alarm and Trip Ground fault GF current levels are monitored and displayed in milliamps The availability of the actual ground fault level gives the user the choice of both alarm and trip levels suitable for the particular installation Using multiple SSRs or a multipole contactor allows all powered legs of non neutral circuits to be switched off under GF conditions Overcurrent Protection A unique overcurrent protection algorithm greatly reduces the possibility of damage to the cir cuit or the controller in the event of a temporary overload while allowing for initially high in rush currents SSR options only Soft Starting Given the circuit breaker size the 920 will limit the energy let through to help prevent nuisance breaker trips due to cable in rush This feature makes the controller particularly attractive for use with self regulating cables SSR options only Minimum Maximum Temperature Tracking The controller maintains the minimum and maximum temperature values seen by the controller since the last reset of these values This is helpful in determining causes of temperature alarms Latching Non Latching Temperature Alarms User selectable non latching temperature alarms allow the controller to automatically clear the alarm when the condition no longer exists High and Low Voltage Alarms
104. nd or CURRENT TURNS RATIO setting C B Limiting This alarm indicates that the controller is limiting the average current to the CIRCUIT BREAKER CURRENT RAT ING setting Excessive current caused by in rush current C B CURRENT RATING setting too low for normal heater cur rent draw or not matched to actual circuit breaker size Incorrect CURRENT TURNS RATIO setting Switch Limiting This alarm indicates that the controller is limiting the average current that is applied to the trace circuit based on the SWITCH RATING setting to protect the solid state relay from excess current Excessive current caused by in rush current Incorrect CURRENT TURNS RATIO setting High Resistance This alarm indicates that the heating cable resistance has deviated from the NOMINAL RESISTANCE setting by more than the HIGH RESISTANCE ALARM setting Alarm setting too close to actual operating resistance NOMINAL RESISTANCE not set properly Open connection wiring problem Damaged cable Incorrect VOLTAGE and or CURRENT TURNS RATIO setting Low Resistance This alarm indicates that the heating cable resistance has deviated from the NOMINAL RESISTANCE setting by more than the LOW RESISTANCE ALARM setting Alarm setting too close to actual operating resistance NOMINAL RESISTANCE not set properly Partial short wiring problem Damaged cable Incorrect VOLTAGE and or CURRENT TURNS RATIO setting EEROM Da
105. nput see sections 3 5 27 on page 28 and 3 6 3 on page 29 Features to reload factory default parameters as well as copy configuration parameters from one point to another are now included see section 3 11 on page 46 New maintenance alarming to track contactor wear see section 3 8 23 on page 42 New Operator Console Features Section1 Overview 1 1 Controllers Covered by this Manual 1 2 Product Overview Monitor PEAK LOAD CURRENT PEAK GFI and the EXTERNAL INPUT STATUS through communi cations see sections 4 3 6 on page 50 4 3 7 on page 50 and 4 3 8 on page 50 The ability to adjust the display scroll rate is now available see section 3 6 10 on page 31 Maintenance data resetting is now supported see section 4 3 on page 49 Display and reset the CONTACTOR CYCLE COUNTER see section 4 3 3 on page 49 Limit the range of the CONTROL SETPOINT setting for 920 Operator Console users see sections 3 5 29 on page 29 and 3 5 30 on page 29 An UNLOCK DATABASE feature was added to the 920 Operator Console s Configuration Mode Main Menu see section 3 10 3 on page 46 The display test no longer occurs at startup instead the user may activate it from a menu option see section 3 10 5 on page 46 This document covers the 920 Series of heat trace controllers and available options The infor mation coincides with the specific releases of firmware for the 920 product which are listed on the cover As Tyco
106. o reset this alarm every time If the par ticular installation includes a Model 780 GCC 9000 this alarm may be left enabled since resets are not considered normal occurrences and the Model 780 GCC 9000 provides the capability to easily log and reset alarms such as these The difference in time between when a COMMUNICA TIONS FAIL ALARM and an HTC RESET ALARM are logged provide an indication of how long the cir cuit has been OFF 3 8 20 CIRCUIT BREAKER LIMITING STATUS SSR ONLY Purpose The circuit breaker limiting feature is always enabled when using an SSR output switch and is intended to prevent the circuit breaker immediately upstream of the controller from trip ping during a temporary overcurrent condition Enabling this alarm will only inform the user that circuit breaker limiting is currently active Alarm Mask ENABLE or DISABLE Procedure Adjust the CIRCUIT BREAKER CURRENT RATING setting to the heating circuit breaker size i e 15 0 or 20 0 amps Enable or disable the alarm as required The CIRCUIT BREAKER LIMITING ALARM need not be enabled in order to adjust the CIRCUIT BREAKER CURRENT RATING setting KA Notes This is a non latching alarm This alarm is advisory If the measured current exceeds the level that would cause the upstream circuit breaker to release the HTC will begin to switch the SSR ON and OFF rapidly to limit the average current to an acceptable level 3 8 21 POWER LIMITING STATUS SSR ONLY Purpose
107. o return the product to the Buyer However the Buyer shall pay all shipping charges duties and taxes for products returned to Tyco Thermal Controls from another country Tyco Thermal Controls warrants that the software and firmware designated by Tyco Thermal Controls for use with the DigiTrace 920 Controller will execute its programming instructions properly Tyco Thermal Controls does not warrant that the operation of the hardware or soft ware or firmware will be uninterrupted or error free The foregoing warranty shall not apply to defects resulting from improper or inadequate mainte nance by the Buyer Buyer supplied software or interfacing unauthorized modification or misuse operation outside of the specifications for the product or improper installation No other warranty is expressed or implied Tyco Thermal Controls disclaims the implied warran ties of merchantability and fitness for a particular purpose The remedies provided herein are the buyer s sole and exclusive remedies Tyco Thermal Controls shall not be liable for any direct indirect special incidental or consequential damages whether based on contract tort or any other legal theory Conducted and Radiated Emissions FCC DOC Statement of Compliance This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interfe
108. on Alarm Mask ENABLE or DISABLE Range 10 to 330 volts VOLTAGE TURNS RATIO 1 00 Procedure Adjust the LOW VOLTAGE ALARM level to the desired value The LOW VOLTAGE ALARM must be enabled to adjust the LOW VOLTAGE ALARM level Also the LOW VOLTAGE ALARM level is affected by the VOLTAGE TURNS RATIO setting The absolute maximum adjusted LOW VOLTAGE ALARM level is 1000 volts The absolute minimum adjusted LOW VOLTAGE ALARM level is 1 volt See section 3 5 21 on page 26 for more information regarding the VOLTAGE TURNS RATIO Notes The LOW VOLTAGE ALARM is only available if VOLTAGE SOURCE is set to the Point being used e The LOW VOLTAGE ALARM should always be enabled Since the HTC may be powered from either of two switch interface modules assuming a dual point installation the loss of power on one circuit will not necessarily be indicated at the alarm output or as a communications failure 3 8 9 LOW VOLTAGE ALARM FILTER TIME SETTING V3 11 AND UP Purpose The LOW VOLTAGE ALARM FILTER will prevent LOW VOLTAGE ALARMS from being indi cated until a low voltage condition has existed for the duration of the LOW VOLTAGE ALARM FILTER time Range 010 12 seconds Procedure Adjust the LOW VOLTAGE ALARM FILTER time to the desired value The LOW VOLTAGE ALARM must be enabled to adjust the LOW VOLTAGE ALARM FILTER time Also the LOW VOLTAGE ALARM FILTER is only available if VOLTAGE SOURCE is set to the Point being used Notes e H an al
109. ontroller This function causes the OVERRIDE SOURCE for each point to be set to REMOTE This is because the EXTERNAL INPUT setting is set to NOT USED 3 11 2 COPY DEFAULTS TO POINT A V3 11 AND UP Purpose Loads the point specific Tyco Thermal Controls default configuration parameters as defined in Appendix F for Point A As well all of Point A s maintenance data are reset All load shedding parameters including fail safe are configured with default values The CONSOLE SET POINT MAXIMUM and MINIMUM are also configured with default values Procedure Enter the Copy Configuration Sub Menu and select DEFAULTS TO A 3 11 3 COPY DEFAULTS TO POINT B V3 11 AND UP Purpose Loads the point specific Tyco Thermal Controls default configuration parameters as defined in Appendix F for Point B As well all of Point B s maintenance data are reset All load shedding parameters including fail safe are configured with default values The CONSOLE SET POINT MAXIMUM and MINIMUM are also configured with default values Procedure Enter the Copy Configuration Sub Menu and select DEFAULTS TO B 3 11 4 COPY POINT A TO POINT B V3 11 AND UP Purpose Copies the point specific configuration parameters of Point A to Point B Point A s con figuration parameters are not changed Procedure Enter the Copy Configuration Sub Menu and select A TO B 4 Notes D e To ensure that the TAGs for both points are not the same Point A s TAG
110. or RS 485 3 9 8 DRIVER Purpose Defines the way the controller s program communicates with the communications interface Setting AUTO or RS 232 or RS 485 or MODEM Procedure Select AUTO to enable the controller to choose the setting that matches the commu nications interface installed 3 9 9 PROFILE Purpose Defines the way the controller s program supports communications handshaking and communication interface signals Setting AUTO or FLOW CONTROL RS 232 or STANDARD 2 2 or 3 WIRE RS 232 or RS 485 or EXTERNAL MODEM Or 1200 BAUD MODEM or 300 BAUD MODEM Procedure Select the PROFILE to be compatible with other devices connected to the controller for communications purposes The setting should be AUTO The controller will automatically select a profile based on the type of communications interface installed in the 920 control mod ule Notes AUTO Selects a communications profile based on the data rate and the type of communica tions interface installed in the control module e FLOW CONTROL RS 232 Continuously asserts RTS Request To Send CTS Clear To Send is required to enable any data transmitted uses DCD Data Carrier Detect to qualify receive data 3 10 Operator Console Functions KA STANDARD RS 232 Continuously asserts RTS CTS is required to initiate a transmit sequence but is ignored once transmitting has begun uses DCD to qualify receive data This is the pro file used when PROFILE AUTO a
111. or contro mode only Purpose This parameter determines the minimum amount of time it will take for a complete contactor ON OFF ON cycle Range 10 to 255 minutes Procedure Adjust the CYCLE TIME setting to yield the desired contactor ON OFF time for a partic ular duty cycle For instance if the contactor should remain on for five minutes with a 50 duty cycle then the CYCLE TIME should be 10 minutes A new duty cycle based on measured control temperature PROPORTIONAL BAND and CONTROL SETPOINT is calculated every time the contac tor is required to change state Notes e Ifthe calculated duty cycle is 0 or 100 then the contactor will not change state and the duty cycle will not be calculated again for a time period CYCLE TIME 30 The minimum cycle time setting is 10 minutes and the minimum controller output duty cycle is 3 This results in a minimum contactor ON time of 18 seconds 3 5 7 SWITCH CURRENT RATING SETTING SSR ONLY Purpose The SWITCH CURRENT RATING setting defines the current rating of the output switch It is used by the controller to limit the maximum average current that will be allowed to flow to the load before it begins to adjust the output duty cycle limiting the amount of current to an accept able level Range 0 3 to 100 0 amps CURRENT TURNS RATIO 1 00 Procedure Adjust the SWITCH CURRENT RATING setting to match the current rating of the output device i e 30 0 amps Note that the SWITCH CU
112. or recommendations and solutions to this problem 3 8 18 SWITCH FAILURE ALARM Purpose The purpose of the SWITCH FAILURE ALARM is to indicate that an output switch failure has occurred The controller determines that if the output switch is turned off and there is load current present then the output switch has failed closed and the alarm is latched on Alarm Mask ENABLE or DISABLE Procedure Enable or disable the alarming of an output switch that has failed in the closed position Ed Note The SWITCH FAILURE ALARM should always be enabled A high temperature condition as a result of a failed circuit can only be caused if the output switch fails closed When an output switch fails closed the controller cannot turn the tracer power off therefore no protection fea tures are available ground fault trip power limiting etc If a SWITCH FAILURE ALARM is detected the unit should be serviced immediately 3 8 19 HTC RESET ALARM Purpose The HTC RESET ALARM is used to indicate 1 Power to the HTC has been interrupted and subsequently restored 2 Atransient has caused the HTC s microprocessor to restart 3 An internal condition has caused the HTC s microprocessor to restart its program Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming on reset as desired KA Note Normally the HTC RESET ALARM is left disabled since powering the controller off and on for maintenance or troubleshooting would require the user t
113. other circuit to determine if the fault moves with the controller If the fault moves with the controller verify that the HTC has been configured cor rectly for the application If the configuration is correct return the controller to Tyco Thermal Controls for evaluation KA Note If the controller does not operate properly and is being returned to Tyco Thermal Controls for service information must be provided as to why the unit was removed from service Contact the Tyco Thermal Controls customer service department for an authorization form and number prior to returning any units for repair 6 1 1 GETTING STARTED To access the functions of the 920 Series HTC use the optional 920 Operator Console If the modem communications option is installed in the 920 control module the Model 780 GCC 9000 Group Communications Controller may also be used to access controller parameters Refer to the operating manual for the particular device that you are using for operational details 6 2 Common Problem Areas The HTC can be used as an effective troubleshooting tool to pinpoint problem areas of heat trace circuits Described below are a few of the more common problem areas their symptoms and parameters to check to determine the actual faulty portion of the heat trace circuit 6 2 1 CONTROL POINT A VERSUS CONTROL POINT B Remember that the 920 series controller is a two point device One of the most common errors is to confuse settings displays or alar
114. output in case of an alarm condition Setting YES Flash or NO Steady Procedure Set the alarm output relay to flash or not to flash on an alarm condition whichever suits the application Notes e If the alarm output is used to drive a pilot light select YES to enable flashing operation When the output is also configured for normally closed operation the pilot light will be on steady for normal operation flash in case of alarm and be extinguished due to a bulb failure or loss of power e f multiple alarm outputs from different controllers are wired in series i e multipoint pan els set this parameter to NO steady 3 6 6 ALARM OUTPUT NORMAL STATE Purpose Configures the alarm output relay for normally open or normally closed operation The normal condition is assumed to be when the HTC is powered and no alarms exist Setting NO Normally Open or N C Normally Closed Procedure Set the alarm output relay to normally open or normally closed to suit the application Note If a pilot light is used for indication of alarms normally closed operation provides a steady illumination of the lamp when the circuit is operating correctly A light that is flashing or out indi cates a fault condition A burned out lamp is readily identified if the HTC is set to flash the alarm output relay in case of alarm See the section 3 6 5 on page 31 3 6 7 LANGUAGE Purpose Defines which language the optional 920 Operator Console uses when
115. prompting the user for input and or displaying messages and status Setting ENGLISH or FRANCAIS Procedure Select the language of choice ENGLISH for English prompts and messages or FRANCAIS for French prompts and messages 3 6 8 POINT B USED Purpose Allows the second control point Point B to be disabled when it is not being used This is an easy method of disabling all ALARMS etc without having to set each parameter Setting YES or NO Procedure Select NO to disable Point B choose YES to use Point B Notes Selecting NO has the following effect on Point B parameters All relevant ALARMS are masked The control output is held off No programming configuration or messages are available using the optional 920 Opera tor Console Complete Point B access remains available using the optional communications interface 3 6 9 PASSCODE See section 3 10 1 on page 45 3 6 10 SCROLL DELAY SETTING V3 11 AND UP Purpose For ease of viewing allows the user to modify the speed at which information is scrolled on the optional Operator Console Range 0 07 to 0 25 seconds 31 3 7 Temperature Alarms 32 Procedure Decreasing the scroll delay value will cause the information on the display to scroll faster Increasing the scroll delay value will cause the information on the display to scroll slower This section defines the temperature related alarming functions of the 920 controller These parameters must be set up
116. rence when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used What s New New Controller Features in accordance with the instruction manual may cause harmful interference to radio communica tions Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense This equipment does not exceed Class A limits for radio emissions as set out in Schedule V to VIII of the Radio Interference Regulations of Communication Canada Cet apparel respecte les limites de bruits radioelectriques applicables aux appareils numeriques de Classe A prescrites dans la norme sur le materiel brouilleur Appareils Numeriques NMB 003 edictee par le Ministre des Communications This section provides a summary of the new features that have been added since the last version of this manual was printed It is assumed that the reader is already familiar with the earlier ver sions of the 920 Controller Alarm filtering is now available for LOW and HIGH TS ALARMS see sections 3 7 7 on page 33 and 3 7 8 on page 34 LOW and HIGH CURRENT ALARMS see sections 3 8 2 on page 35 and 3 8 4 on page 36 HIGH GFI ALARMS see section 3 8 6 on page 36 LOW and HIGH VOLTAGE ALARMS see sections 3 8 9 on page 37 and 3 8 11 on page 38 LOW and H
117. rom modifying the CONTROL SETPOINT temperature setting to a dangerous level 3 5 2 ALPHANUMERIC TAG ASSIGNMENT Purpose A 19 character alphanumeric TAG may be assigned to a control point to allow it to be easily associated with a pipe vessel process circuit drawing name or number Setting Any combination of 19 characters from A Z 0 9 or Procedure Using the 920 Operator Console enter the desired text Refer to the separate DigiTrace 920 Series HTC Operator Console Installation and Operating Instructions Tyco Ther mal Controls reference H56903 for TAG entry information 3 5 3 SWITCH CONTROL MODE Purpose This allows selection of the type of algorithm to be used by the HTC to maintain the CONTROL SETPOINT temperature There are four different control algorithms available in the HTC proportional proportional ambient SSR proportional ambient contactor and deadband See section 5 2 on page 50 for a complete explanation of these controlling techniques as imple mented in the HTC Setting PROPORTIONAL PROPORTIONAL AMBIENT SSR V3 11 PROPORTIONAL AMBIENT CON TACTOR V3 114 or DEADBAND Procedure Select the desired control technique Note that deadband control and proportional ambient contactor should be selected when using contactors or when precise control and advanced current handling functions are not required Note If deadband is selected a DEADBAND setting will be available in the HTC configuration m
118. s applied to the controller it determines if load shedding mode has been enabled If enabled the controller immediately enters load shedding operation holding its output off and waits to see if the GCC or an external communicating device has initiated a load shedding com mand If no command is present the controller resumes normal operation If a load shedding command is present the controller will continue to hold the output OFF until one of three condi tions occurs 1 The GCC contact input or zone definition bits of an external communicating device which ini tiated load shedding clears and the command to terminate load shedding mode is issued 2 Communications are interrupted between the controller and its communicating device as in the case of a damaged communications wire Approximately 30 seconds after communica tions ceases the controller will return to normal operation 3 Communications between the controllers and the external communicating device goes off line for approximately two minutes as occurs when the 760 Hand Held Programmer is used to communicate with the controller Note The controller will return to normal operation if communications between the 780 or exter nal communicating device and the controller are disrupted in any way This will return tempera ture control to the HTC Also the HTC does not perform a periodic autocycle test while operating in load shed mode When using a GCC it must be configured for load sh
119. s been enabled PASSCODE is not set to 0 and the user has unlocked console modification access to the controller s configuration parameters the LOCK DATABASE feature allows the user to re lock this modification access once programming has been completed 45 KA Procedure Select the LOCK DATABASE function at the end of the Configuration Mode Main Menu to lock out 920 Operator Console configuration modification access The display will confirm the operation by displaying a DATABASE LOCKED message Note 920 Operator Console configuration modification access will automatically re lock after approximately 5 minutes of keypad inactivity 3 10 3 UNLOCK DATABASE Purpose f a PASSCODE has been enabled PASSCODE is not set to 0 and the user wants to mod ify any of the controller s configuration parameters using a 920 Operator Console the database must first be unlocked Procedure Try modifying any configuration parameter or select the UNLOCK DATABASE function at the end of the Configuration Mode Main Menu for V3 11 and up and a prompt for the PASSCODE will appear If the correct PASSCODE is entered the display will confirm the operation by displaying a DATABASE UNLOCKED message 3 10 4 TEST TRACING Purpose The TEST TRACING feature provides an easy method of temporarily overriding the tem perature control without having to modify the CONTROL SETPOINT temperature or any other con figuration parameter Procedur
120. s ensure that the power to the unit is turned off during installation or removal to avoid the risk of injury and damage to the controllers Warning Explosion Hazard Do not install or remove the control module while the unit is powered Fig 2 1 Control module installation The 920 series controller is designed to be mounted to a flat back plate panel using a terminal board This plug in design simplifies installation and maintenance by allowing all of the low voltage field wiring to remain undisturbed while a control module is installed or removed Installation of the control module is easily accomplished by plugging it into the connector on the terminal board The module is fully inserted once its rear cover is flush to the top surface of the terminal board The connectors are designed to be self aligning so no undue force should be required Next secure the module using the two captive screws provided one located on each side of the rear cover These should thread easily into the terminal board Be sure to align the screws properly to avoid cross threading them To remove the control module loosen the two captive screws Once they have been completely loosened they will float freely in their respective retaining collars without falling out The module may now simply be pulled straight out of its connection 2 6 2 OPERATOR CONSOLE INSTALLATION AND REMOVAL The operator console is designed to be easily installed or removed wh
121. se setting is that it inevitably leads to nuisance alarms particularly when voltage fluctuations are present By using the HIGH RESISTANCE ALARM nuisance alarms due to voltage dips may be minimized Use of the HIGH RESISTANCE ALARM assumes that the controller power is derived from the same circuit as the tracing power either by direct connection or through a step down trans former Disable this alarm if the controller is powered from a separate circuit e Be careful when using this alarm feature with heating cables that exhibit a variable resistance with temperature High resistance alarming may not be as effective if the load has a decreas ing resistance with temperature e No HIGH RESISTANCE ALARMS will be generated if the measured voltage is below the LOW VOLTAGE ALARM setpoint regardless of whether the LOW VOLTAGE ALARM is enabled This stops an alarm from being generated when the circuit power is turned off If the LOW VOLTAGE ALARM is disabled ensure that the LOW VOLTAGE setpoint is set to a relevant level otherwise no HIGH RESISTANCE ALARMS will occur e HIGH RESISTANCE ALARMS will only be generated if the output switch is on 3 8 15 HIGH RESISTANCE ALARM FILTER TIME SETTING V3 11 AND UP Purpose The HIGH RESISTANCE ALARM FILTER will prevent HIGH RESISTANCE ALARMS from being indicated until a high resistance condition has existed for the duration of the HIGH RESISTANCE ALARM FILTER time Range 0 to 12 seconds Procedure Adjus
122. sign is normally done assuming worst case conditions where 100 of the design output power is required to maintain the desired minimum temperature When the ambient temperature is above the design minimum but some heat is still required adjusting the PROPORTIONAL BAND width accordingly will allow only the amount of power required by the application to be con sumed while maintaining the minimum required temperature Example A water line must be protected from freezing when the ambient temperature falls below 10 C Either the proportional ambient SSR or proportional ambient contactor mode is selected as the control method depending on the type of switch being used The heater and insulation are chosen to impart enough heat to the line to keep it from freezing at a worst case ambient temperature of 40 C At 10 C the heater should be completely off since no heat is required at this temperature to guarantee that the product will not freeze It follows that the amount of heat required by the water line decreases as the ambient temperature increases from 40 C to 10 C theoretically at 15 C the heater output should be approximately 50 Setting 21 22 the CONTROL SETPOINT temperature to 10 C and the PROPORTIONAL BAND to 50 C will force the controller s output to be 100 on at 40 C 50 on at 15 C and off at 10 C 3 5 5 DEADBAND SETTING Deadband control mode only or if a point controls an INHIBIT output signal Purpose Whe
123. sing proportional ambient SSR control since ambient temperature is being monitored rather than pipe temperature 5 2 4 PROPORTIONAL AMBIENT CONTACTOR CONTROL FOR USE WITH EXTERNAL CONTACTORS When an HTC using a contactor is used to control the output based on the ambient temperature this control mode should be used Proportional ambient contactor control on the HTC is implemented as follows The output may not be switched on off rapidly when using a contactor so proportional tem perature control is implemented by applying the required duty cycle over the selected CYCLE TIME The output is fully on for a portion of the CYCLE TIME as determined by the calculated duty cycle and it will be completely off for the remainder of the CYCLE TIME The duty cycle is calculated each time the output toggles based on the ambient temperature PROPORTIONAL BAND setting and the CONTROL SETPOINT temperature setting The controller monitors the ambient temperature and compares it to the CONTROL SETPOINT temperature as in proportional ambient SSR control If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting power is applied to the trace with a duty cycle of 100 The controller output will be fully on for 1 30th of the CYCLE TIME setting before the duty cycle is calculated again e fthe temperature sensed by the control sensor is equal to or greater than the CONTROL SET POINT t
124. ss than the AUTOCYCLE INTERVAL otherwise auto cycling could affect the duty cycle e fan AC ALARM becomes active during an autocycle but the AUTOCYCLE INTERVAL expires prior to the corresponding ALARM FILTER time then auto cycling will continue until the ALARM FILTER time has elapsed e For the earliest possible alarming of heating circuit problems the AUTOCYCLE INTERVAL should be set to a small value 3 5 25 AUTOCYCLE TIME UNITS Purpose The autocycle time units parameter allows selection of minutes or hours for the AUTOCYCLE INTERVAL setting Setting HOURS or MINUTES Procedure Set the AUTOCYCLE UNITS to the desired time units 3 5 26 INHIBIT CONTROL V3 00 ONLY Purpose This feature allows the HTC s EXTERNAL INPUT to override the controller s temperature control and force the output switch off This is especially useful when the user wishes to turn a controller or a group of controllers off over the summer months during maintenance or when a line is flowing and does not require heating 27 28 Setting ENABLE or DISABLE Procedure Enable or disable the INHIBIT CONTROL for the control point being programmed Notes The EXTERNAL INPUT must also be programmed as INHIBIT before this parameter can be set See section 3 6 3 on page 29 for further details e If the autocycle feature is enabled it will continue to function even when the INHIBIT mode is active Fail safe mode is inactive if the INHIBIT mode is active e
125. t the HIGH RESISTANCE ALARM FILTER time to the desired value The HIGH RESIS TANCE ALARM must be enabled to adjust the HIGH RESISTANCE ALARM FILTER time Notes e Ifan alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated fthe user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired 3 8 16 NOMINAL RESISTANCE SETTING Purpose This parameter defines the nominal expected heater resistance A value must be entered by the user to allow the HIGH and LOW RESISTANCE ALARMS to be used In installations where the power source may experience periodic fluctuations surges and or brown out condi tions alarming on resistance deviation offers an improved method of monitoring tracer integ rity over simple LOW and HIGH CURRENT ALARMS Since the ratio of voltage to current is 39 40 monitored the HIGH and LOW RESISTANCE ALARMS offer cable monitoring that is relatively immune to voltage fluctuations Range 2 00 to 2000 00 9 Procedure The NOMINAL RESISTANCE value can only be set if either the LOW RESISTANCE and or the HIGH RESISTANCE ALARMS are enabled Once the controller and the heating cable have been installed the following procedure should be used to determine the NOMI
126. ta Failure This alarm indicates that the controller has detected a failure in its nonvolatile memory this is where all of the controller s configuration and calibration settings are stored This indicates an internal problem and the HTC should be replaced and returned to Tyco Thermal Con trols for repair The HTC cannot bypass the failed area of its memory and has loaded factory defaults into this failed area Contactor Count V3 11 and up This alarm indicates that the number of off to on transi tions of a contactor has exceeded the CONTACTOR COUNT ALARM setting and needs to be replaced Contactor may be worn e Some configuration parameter i e DEADBAND AUTO CYCLE INTERVAL load shedding etc is causing the contactor to toggle more than usual 59 Section 7 Maintenance 7 1 Operator Maintenance 7 2 Replaceable Parts 60 The 920 series controller is designed to be a maintenance free product Once installed properly the only maintenance required 15 retightening of the terminal connections approximately one week after installation and inspection periodically thereafter Also alarm pilot lamps if installed and contactors may need periodic replacement Caution Make sure that the power to the controller is OFF when replacing the pilot lamps Also be certain power to the controller is OFF before attempting to test or service the heat tracing Do not rely on the controller as a disconnect device There are
127. tal V3 X Iphase X Viine line Where Iphase the adjusted phase current being measured and Viine line the adjusted voltage reading being measured The VOLTAGE and CURRENT TURNS RATIOS affect both calculations 4 3 Maintenance Data 4 3 1 MAX MIN TEMPERATURE VALUES MAX CONTROL TEMP MIN CONTROL TEMP TS 1 MAX TEMP TS 1 MIN TEMP TS 2 MAX TEMP TS 2 MIN TEMP Purpose This feature indicates the maximum and minimum temperatures ever recorded by the HTC since the last time the values were reset It may be useful to log the maximum minimum temperatures ever experienced on a particular trace circuit for the purposes of troubleshooting or gathering data for future design criteria The temperature values are written to the controller s nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user maximum minimum temperatures are recorded for TS 1 TS 2 and the CONTROL TS Range Can only be reset cleared by the operator Procedure The maximum minimum temperatures can be reset using the optional 920 Operator Console V3 11 or a communicating device Resetting any one of the temperatures will reset all of them 4 3 2 POWER ACCUMULATOR Purpose This feature indicates the total power consumption of the trace circuit since the last time the POWER ACCUMULATOR was reset It may be useful to log the amount of power con sumed on a particular trace circuit for the purposes of energy management or gathering data
128. tch when the control temperature becomes less than the highest LOW TS ALARM temperature if the following conditions are met Fail safe mode is enabled Load shedding is active The TS CONTROL MODE uses both TS 1 and TS 2 Both TS 1 and TS 2 have their LOW TS ALARMS enabled e A FORCE ON override signal has higher priority than a load shedding signal An INHIBIT signal has higher priority than fail safe mode TEMPBUS is short for Temperature Bus This refers to a connection that allows one master HTC to share its control temperature with a number of slave HTCs Up to 25 slave HTCs can be connected to this bus Refer to the wiring diagrams in Appendix C for example connection details 53 5 4 1 TEMPBUST MASTER Only Point A of a 920 HTC can be configured as a TEMPBUS master A TS CONTROL MODE using either TS 1 and or TS 2 should be selected and the EXTERNAL OUTPUT should be set to TEMPBUS This will cause the measured control temperature of Point A to be sent out the EXTERNAL OUTPUT port VA Notes D e H a TEMPBUS master has its temperature control overridden by an INHIBIT override or a FORCE ON override signal it will pass this override signal over the TEMPBUS to its slaves Load shedding fail safe or auto cycling conditions are not passed over the TEMPBUS from a master to its slaves 5 4 2 TEMPBUS SLAVE Both Point A and or Point B of a 920 HTC can be configured as a TEM
129. ted resistance value that can be cross referenced to the RTD table DIN Standard 43760 found in Appendix D on page 74 or Appen dix E on page 75 Compare the measured resistance and cross referenced temperature value obtained from the RTD table to the indicated or displayed value These should agree to within the accuracy standards of the HTC and the RTD To verify the Controller Turn off the power to the controller before proceeding e Disconnect the RTD wiring from the input terminals e Connect a 100 Q resistor across the source or sense terminal and common Insert a jumper between the source and sense terminals e Apply power to the controller The indicated or displayed temperature should be about 0 C 32 F depending on the actual resistance of the test resistor if TS TYPE is set to 100 Q Platinum 3 Unstable or Bouncing Temperature An erratic indication of temperature can be caused by several factors external to the controller however a bouncing temperature of a few degrees should not be confused with incorrect opera tion The controller s accuracy and resolution will result in an indicated temperature change of a couple of degrees if the measured resistance temperature falls between two discrete values This is sometimes referred to as quantization error If the bounce or instability is excessive check Wire used for extension of the RTD should be three wire twisted and shielded with the shield grounded at the controller on
130. the following text Front Display The control module includes LED status indicators to show output and alarm conditions Using the optional 920 Operator Console the setpoint temperature actual control temperature and load current are immediately accessible to plant operators and maintenance staff The display units are field selectable for F or C 40 F to 140 F 40 C to 60 C Operation Extended temperature operation permits installation in all but the harshest environments SSR output modules are limited to operating ambient temperatures of 104 F 40 C without derating Single or Dual Temperature Sensor Inputs The ability to use one or two temperature sensor TS inputs for each control point allows the selection of one of eleven control modes and programming of all temperature parameters High and Low Temperature Alarms High and low temperature alarms are offered for both inputs of each control point High and Low Current Alarms Low current alarm is more than just a continuity level alarm The 920 offers full adjustment over the entire current measurement range for both high and low current alarm limits Solid State or Contactor Output The 920 is available with externally mounted solid state relay SSR output switches or contac tors With the SSR option the user may select a time proportional control algorithm a simple deadband mode or one of two ambient control algorithms The contactor versions always use either the deadba
131. til the entire alarm filter time has expired 33 3 8 Other Alarms 34 3 7 8 HIGH TEMPERATURE SENSOR ALARM FILTER TIME SETTING V3 11 AND UP Purpose The HIGH TS ALARM FILTER will prevent HIGH TS 1 and or HIGH TS 2 ALARMS from being indicated until their corresponding alarm condition has existed for the duration of the HIGH TS ALARM FILTER time Range 0 to 999 minutes Procedure Adjust the HIGH TS ALARM FILTER time to the desired value Note that either the HIGH TS 1 ALARM and or the HIGH TS 2 ALARM must be enabled in order to adjust the HIGH TS ALARM FILTER time Notes e H an alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e ifthe user resets an alarm while the alarm condition is still exists the alarm will not be indi cated again until the entire alarm filter time has expired The HIGH TS ALARM FILTER time setting does not affect the cutout time when the HIGH LIMIT CUTOUT feature is enabled 3 7 9 LATCH TEMPERATURE SENSOR ALARMS SETTING Purpose This allows for the selection of automatic clearing of all HIGH and LOW TS ALARMS non latching when a temperature alarm condition no longer exists or permanent alarming of such a condition latching until the alarm is manually reset Setting YES LATCHING or NO NONLATCHING Procedure Adjust
132. ting NO or YES Procedure If an automatic 3 phase power calculation is desired select YES If a normal power calculation is desired select NO Note For the total 3 phase power calculation to be accurate the following conditions must be met e All three phases must be balanced and star Y connected The measured corrected current is one of the phase currents The measured corrected voltage is the line to line voltage The formula used to calculate this total power is Piota V3 X lphase X Viine line 3 5 11 TS FAIL MODE V3 11 AND UP Purpose This parameter determines whether the HTC turns the output switch ON or OFF if all selected temperature sensors fail to provide a control temperature 23 24 Setting OFF or ON Procedure If the HTC should turn the output switch off when it cannot read a valid control tem perature then select OFF otherwise if the output switch should turn on then select ON Note This parameter is part of the T5 CONTROL MODE 3 5 12 TEMPERATURE SENSOR CONTROL MODE Purpose The TS CONTROL MODE allows the selection of one of eleven possible temperature con trol modes for the controller The different modes allow redundant fail safe temperature sensing averaging or minimum maintain temperature control Setting Select one of the following eleven possible modes Control TS and Description CONTROL USING TS 1 FAIL OFF ON CONTROL USING TS 1 FAIL TO TS 2 CONTROL USING TS 2 FAIL OFF ON CO
133. ting Environment 12 2 5 Installation Location o s cees cse cne III 12 26 Mounting Procedures Af pa am anal a a E de d seg PT 13 LIN EE 14 Rit Kale TEEN 17 PASTULAN 18 Section 3 Programming and Configuration cece sn 18 SEN NIO UNO EE 18 32 Front Panel Featutes AA id 19 3 3 920 Operator Console Display 0 ccc cece eee 19 3 4 920 FUNCION Sci e EELER NG ebay duet E pt pond da Nh PAL Ae ds 20 3 3 Control Point Setup ceci AE rd 20 3 6 Common Controller Setup ss 29 3 7 Temp ratur e Alarm 22 oso rex eR ba EE toe ae Raw E AE Ri 32 3 0 Other AS asa paaa ebe Reti e adeeb e BARETA Pe ee dons sands hud eh s 34 3 9 Communications Setup 00 c cece cece cece cece a 42 3 10 Operator Console Functions 45 3 11 Copy Configuration Functions V3 11 and up cece eee eee eee eee 46 Section 4 Monitored Parameters 0 0 47 Al 101000001100 ure o pU PALA AEG Eie Er RENS 47 4 2 Analog ReadingS 0 III e 47 4 3 Maintenance Datas a ra A DER RR pee BABA nah Pha phd hh d Se be el 49 Section 5 Control Moes 50 5 1 IFtFOQUCHOT ier pe geg EE Seat a jana ee 50 5 2 Switch Control Modes 50
134. unless the TS 2 HIGH LIMIT CUTOUT feature is enabled KA Note If no second sensor is installed disable this alarm This alarm may be used for applica tions where a product that is sensitive to over temperature is involved General usage could result in nuisance alarms due to the flow of hot product or steam out This may be a case where the alarm could be enabled and non latching temperature alarming used A high temperature condition resulting from a forced on failure of the heating circuit should first be alarmed by the SWITCH FAILURE ALARM See section 3 8 18 on page 40 for more information 3 7 7 LOW TEMPERATURE SENSOR ALARM FILTER TIME SETTING V3 11 AND UP Purpose The LOW TS ALARM FILTER will prevent LOW TS 1 and or LOW TS 2 ALARMS from being indicated until their corresponding alarm condition has existed for the duration of the LOW TS ALARM FILTER time Range 0 to 999 Minutes Procedure Adjust the LOW TS ALARM FILTER time to the desired value Note that either the LOW TS 1 ALARM and or the LOW TS 2 ALARM must be enabled in order to adjust the LOW TS ALARM FILTER time VA Notes e Ifan alarm condition appears and then disappears before the alarm filter time has expired the filter timer is reset and the alarm condition must exist again for the entire alarm filter time before the corresponding alarm will be indicated e fthe user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again un
135. usted circuit voltages The VOLTAGE TURNS RATIO is not used if the selected VOLTAGE SOURCE is not from the dedi cated switch interface 3 5 22 CURRENT TURNS RATIO ADJUSTMENT Purpose The CURRENT TURNS RATIO adjusts current readings for applications where a controller is monitoring a load through an external step up or step down current transformer Range 0 10 to 60 00 TO 1 Procedure Adjust the CURRENT TURNS RATIO to equal the ratio of the primary to secondary windings of the external current transformer Compare the indicated current to the measured current after setting of the CURRENT TURNS RATIO and adjust until the two readings are as close as possible KA Note When the CURRENT TURNS RATIO has been set appropriately the HTC will calculate the cir cuit power using the adjusted current and voltage readings Current alarms as well as the switch and circuit breaker limiting functions also use the adjusted circuit currents 3 5 23 AUTOCYCLE ENABLING Purpose The autocycle function momentarily approximately 10 seconds applies power to the heating circuit at the selected interval It is used to test the integrity of the heating circuit Alarms present at the time of autocycle then become latched and remain active after the completion of the autocycle function Auto cycling effectively eliminates the need for preventive maintenance by automatically verifying the heating circuit integrity Setting ENABLE or DISABLE Procedur
136. ve data 6 Data carrier detect 7 Clear to send 8 Transmit data 22 Request to send 23 Common 24 Modem Interface Connections Note that these particular signals are not polarity sensitive Communication Signal Terminal No Modem 6 Modem 22 Shield 8 Shield 24 2 7 5 POWER CONNECTIONS All of the power terminals are numbered for easy identification Do not attempt to use wire sizes that exceed the marked terminal ratings and avoid terminating two wires on the same terminal whenever possible Always be sure that all terminals are adequately tightened according to the terminal manufac turer s specification See Appendix A on page 61 for allowable wire sizes recommended insula tion strip lengths and tightening torque A loose terminal can cause arcing and damage to the terminal or incorrect operation of the controller Note Make sure that power terminals are re tightened several days after installation Stranded wire will tend to compress when initially installed therefore these terminals should be checked for tightness several times after the system is installed to ensure that a good connection is main 2 8 Initial Power up MA tained Be certain to use the proper size screwdriver for the terminal blocks to minimize the chance of damage to the terminals If the controllers are installed in either a metallic or non metallic enclosure follow the enclosure manufacturer s recommendations for proper grounding Do not rely
137. vely high current condition is present The con troller pulses its output switch for a small number of cycles and reads the resulting current If the measured current exceeds the SWITCH RATING setting the duty cycle of its output switch will be varied so that an average current not exceeding the SWITCH RATING setting is maintained Alarm Mask ENABLE or DISABLE Procedure Adjust the SWITCH CURRENT RATING setting to the actual current rating of the SSR Enable or disable the alarm as required The SWITCH LIMITING ALARM need not be enabled to adjust the SWITCH CURRENT rating setting Notes e This is a non latching alarm e This alarm is normally enabled Currents in this range cannot be considered normal and should be investigated 3 8 23 CONTACTOR COUNT ALARM V3 11 AND UP Purpose Generates an alarm if the number of off to on transitions of a contactor reaches or exceeds the CONTACTOR COUNT ALARM setting This serves as a method to perform preventative maintenance on the contactor before a failure is likely to occur Alarm Mask ENABLE or DISABLE Range 0 to 999999 off to on transitions Procedure Adjust the CONTACTOR ALARM setting to the desired value The CONTACTOR ALARM must be enabled to adjust the CONTACTOR ALARM setting Note The CONTACTOR ALARM is only available if the SWITCH CONTROL MODE is set to either DEAD BAND or PROPORTIONAL AMBIENT CONTACTOR 3 8 24 EEROM DATA FAILURE ALARM Purpose The EEROM DATA FAILURE ALARM ind
138. vice Both control points allow completely independent operation and as such have their own individual settings that must be configured Throughout the text the first control point is referred to Point A and the second as Point B 3 2 Front Panel Features 3 3 920 Operator Console Display Ed Power On LED DigiTrace PROGRAMMABLE DUAL POINT HEAT TRACING CONTROLLER Communications status 920 SERIES indicators CONSOLE INTERFACE A POWER Operator Alarm status EH TRANSMIT oO o console indicators REENE connection Output status E indicators A 20910 B 20911 tico Flow Control Tyco Thermal Controls Communications addresses for Control Point A and Control Point B Fig 3 1 DigiTrace 920 front panel Front panel features of the heat trace controller are shown in Figure 3 1 The remainder of this Section describes the front panel status and display LEDs 3 2 1 920 FRONT PANEL DISPLAY The basic 920 series control module front panel includes seven LED indicators Four of these are used to indicate the Output and Alarm status of control points A and B Status LEDs OUTPUT The OUTPUT LED when illuminated steadily indicates that the output of the controller is turned on and is allowing current to flow in the trace circuit For SSR versions a flashing LED indicates that the controller is pulsing its output on and off to maintain the setpoint
139. will allow disabling of the slave controllers during the summer months during a maintenance shutdown etc A TEMPBUS master may be useful when a number of slave controllers do not have their own temperature sensors and are set to control the ambient temperature Setting NOT USED TEMPBUS V3 11 or INHIBIT Procedure Select NOT USED if Point A is not a master controlling the EXTERNAL OUTPUT port Select INHIBIT if Point A will be controlling the EXTERNAL OUTPUT port as an INHIBIT master Select TEMPBUS if Point A will be sending its control temperature out the EXTERNAL OUTPUT port For TEMPBUS operation description see section 5 4 on page 53 Notes The master and slave controllers must be installed in the same enclosure The EXTERNAL OUTPUT PORT signal is not intended to be connected over extended distances or between enclosures e If EXTERNAL OUTPUT is set to INHIBIT then the DEADBAND parameter for Point A will be used to define the operation of the EXTERNAL OUTPUT port even though the SWITCH CONTROL MODE for Point A may not be set for DEADBAND operation See section 3 5 5 on page 22 for additional details regarding the DEADBAND mode e f the EXTERNAL INPUT PORT input is not being used Point B may be configured as a slave for a controller with its Point A configured as a master 3 6 5 FLASH ALARM OUTPUT SETTING Purpose Programs the alarm output relay for flashing or steady

DigiTrace® 920 Series Heat Trace Controller

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DigiTrace&reg; 920 Series Heat Trace Controller

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DigiTrace® 920 Series Heat Trace Controller