Heated Line and Model 530 Temperature Controller User Manual
Contents
1. This component must be provided with adequate heat sinking The heat sink should be chosen to keep the baseplate temperature below 90 C when dissipating 30 watts The effect of ambient temperature must be taken into account In some circumstances fan assisted cooling will be necessary Refer to the installation drawing for wiring information 5 Operation CAUTIONI Take care to avoid skin contact with the line ends while disconnecting and transporting a hot line Tightly coiling a hot line can cause the PTFE inner tubing to kink causing restricted flow next time it is used Switch the CONTROLLER off and allow cool air to purge through the line until it is cool about 60 C to 70 C If the line must be transported while still hot only LIGHTLY coil it 1 2 Set the temperature control to the required position Apply power to the unit Confirm that the POWER light is on Confirm that the HEATER light is on and cycles on and off when the operating temperature is reached The proportional band control has been factory set for a 40 C band This is the range over which power is proportionally applied and is centered around the set temperature If the temperature control accuracy needs to be improved then the proportional band should be reduced If the temperature overshoots the set point by an unacceptable level then the proportional band should be increased A small screwdriver can be used to adjust the P BAND control accessible from th2. A au pem BEN Bet MUNDELL l KRYR TFIHYOSENBYL E y e a tf S ww ari MG 3LOSN i i HAYA A NOPLIQADOUL FIONY T Figure 3 530 Installation standard
3. HEATED LINE AND MopEL 530 TEMPERATURE CONTROLLER USER MANUAL Table of Contents 1 Introduction HEATED LINE 3 2 Introduction MODEL 530 TEMPERATURE CONTROLLER 3 3 OPECITICAION 2224 das See eee pt eR Eaa heehee awakusqa ee aed Ge la al Ca us 4 4 Installation cote Ae ia eee eS Ae ye he en eS 5 4 1 Power Connections and Fuse Selection 5 4 2 Thermocouple and Other Connections 5 4 3 Alarm Connections optional _ 5 4 4 Voltage Setting optional _ e e 6 4 5 External Solid State Relay optional 6 5 Operation 424m duy RR DAA A Ew EORR RUM E BEER EER doe A es baw ee ed 7 List of Figures ee Figure 1 530 Connector 0 ccc ete hr 5 Figure 2 530 Installation 2 5 kW Loads ooooooooooorr rh 8 Figure 3 530 Installation standard o o oooooooorrr rh 9 1 Introduction HEATED LINE The SIGNAL HEATED LINE was primarily developed for carrying heated diesel exhaust gas to hydrocarbon and NO analyzers such as the SIGNAL 3000 AND 4000 SERIES If the temperature of the sample gas falls below the dew point of the gas being measured then the gas will condense and become liquid in the sample line Since the analyzers can only
4. controller SIGNAL MODEL 530 which has been designed to drive the primary side of the isolating transformer This gives a lower power loss in the CONTROLLER Special circuit techniques are used to reduce the high inrush current normally associated with transformer loads and ensure that the DC component of the drive current is minimized 2 Introduction MODEL 530 TEMPERATURE CONTROLLER The 530 TEMPERATURE CONTROLLER is designed to control the temperature of the SIGNAL HEATED SAMPLE LINE The advantage of this unit is the ability to drive the primary side of the line transformer The high surge current that can occur at switch on is significantly reduced by special circuit techniques giving improved reliability and reduced line interference This feature is not available on most standard temperature controllers An output is available to drive a solid state relay for loads greater than specified The user must ensure that adequate heat sinking is provided for the relay The CONTROLLER can be fitted with an alarm option This option provides two sets of changeover contacts which operate when the sample line temperature is below 150 C or above 200 C Wo 3 Specification 1 Mains supply 2 Load a standard unit b with external drive unit Part No REL 001 200 260 Vac 50 60 Hz 3 Temperature control range 4 Proportional band 5 Size 6 Weight 7 Ambient Temperature 8 Relative Humidity 9 Fuse Rating 10 Alarm contact
5. e front panel One turn anticlockwise will reduce the proportional band by about 4 C One turn clockwise will increase it by about 4 C Adjust until an acceptable control is achieved If the T C FAULT light is on then a fault exists in the line thermocouple or in its connections to the CONTROLLER Check for a low resistance between the thermocouple leads and for a high resistance between the thermocouple leads and the heater leads Trace the leads through to the CONTROLLER and transformer and confirm that they are correctly wired p SYGT MA S Z 600201 ibn ee MUYTILIS MY OES miu ND ZEN a h a yr 9 a OF l E QUA SANA TALS CTI ios d sare oa si ae as ala CHALIAND MESE A o E Ed EIL C 7 amp ES Q LV eS E juan ru mL y Md N MG NACUSA Fla PO WL te DU Figure 2 530 Installation 2 5 kW Loads SHU 1 dero BINDON cedi af A s LAA s OR ELLE p esnada itia pais di AEA Oey x m SNC I N3 MIC torta Sy e xa j lal 07 a gt TET 130 ANAL TENDIS Suc ot un e HARO 3 E new SALON Q3191S sa iin gazy DL 1189 Le c 3 4 p YN E NAPUIA iDariouu3 t e Jf fa Ql LMLN umi c MARLAA OLNI JLO E LIL AOS TORK ALIADA L I JA TL wu L A D L 1 AA ITA IIA E HL enel d C I aE Aye Ory aono 156 WX OFS MOT Wales aoe Hower 009135 sm wao SN TS Suc meo Fae
6. for solid state relay ve 2 3 Control output return a 4 Not used 4 5 Temperature output return 6 Temperature output 10 mV C Figure 1 530 Connector 7 8 Thermocouple ye 4 3 Alarm Connections optional The alarm contacts are presented on a 9 way male d type connector mounted on the rear panel Pin detail is as follows Alarm 1 COM Pin 2 N O Pini N C Pin6 Alarm 2 COM Ping NO Pin7 N C Pin3 4 4 Voltage Setting optional The CONTROLLER is factory set for the mains voltage requested To change the operation voltage it is necessary to remove the top cover WARNING Removal of the covers will expose the mains terminals and wiring To ensure safety always disconnect the unit from the mains supply and only allow qualified personnel to gain access Remove the top cover Identify SW1 between the main connector and the transformer Set the switch to the 120V or 240V position according to the mains supply available Refit the cover Please ensure that you do not try to use a transformer on the wrong supply voltage Changing the switch in the 530 does not alter the transformer rating 4 5 External Solid State Relay optional When extra long lines are to be driven up to a maximum of 55 meters 28 meters for 120 Vac a solid state relay part No REL 001 must be used to drive the transformer It is important that only SIGNAL approved components are fitted to preserve the low surge current and noise features
7. measure gases it is essential to avoid such condensation A constant high temperature must be maintained throughout the entire line assembly and this is achieved by the use of a braided heating element The braiding is made from stainless steel wire which completely surrounds an inner PTFE tube The whole is bedded in a silicone sponge for thermal insulation and a sleeve of wire reinforced anti scuff PVC hosing completes the assembly This method of heating ensures a constant high temperature throughout the sample line with no cold spots Despite internal temperatures of up to 200 C the efficiency of the insulation keeps the line relatively cool on the outside and therefore quite comfortable to handle The temperature of the braid is sensed by a type K thermocouple in thermal contact with but electrically isolated from the braid The thermocouple leads and electrical terminations to the braid are brought out at one end of the line for connection to the TEMPERATURE CONTROLLER and isolating transformer Heating is achieved by passing a current through the braid to raise its temperature SIGNAL has designed the heating method with safety as a major consideration and therefore an isolating transformer is supplied with the line This transformer is designed and wound to suit an individual line according to the voltage required to drive the correct current through the length of braid Temperature control is achieved by a solid state purpose built
8. rating 11 Factory settings 100 130 Vac 50 60 Hz Internally selected 1800 watts 240 Vac 900 watts 120 Vac 5000 watts 240 Vac 2500 watts 120 Vac Screwdriver adjustable 0 100 C 1 turn 0 4 C DIN standard 96 x 96 mm 195mm overall length 200mm required behind panel 27mm required in front of panel 900 grams 5 40 C ambient temperature 9096 non condensing Depends upon length of heated line and mains supply 0 200 C set by front panel control 1A at 30Vdc or 0 3A at 150Vac maximum current 1 254 Maximum voltage 150V Check the serial number plate for details The unit is supplied with the correct fuse to suit the heated line and with the mains selector set to 240 volts Heat sinking is required for the external drive component Its baseplate temperature must not exceed 90 C Maximum power dissipation is 30 Watts 4 Installation 4 1 Power Connections and Fuse Selection Power and transformer connections are made at the terminal block on the rear panel They are labeled as follows going from left to right Hi Transformer switched neutral H2 Transformer live L Power Live N Power Neutral Earth When the CONTROLLER is supplied together with a heated line and transformer a suitable rated fuse is factory fitted 4 2 Thermocouple and Other Connections Input and output connections are made at the rear panel 8 pin DIN connector as shown below 1 Thermocouple ve Not used D Control output
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