Home

DigiTrace® 910 Series Heat Trace Controller

1. 73 Appendix D HTC Load Shedding 74 Appendix E 100 Q Platinum RTD Table 75 Appendix F 100 Q Nickel Iron RTD 76 Appendix G Factory Default Configuration V3 1X TI 910 Series HTG die esee bbs beeen sehen a kas 77 DigiTrace 910 Series Heat Trace Controller Certification Limited Warranty Warranty Exclusion Disclaimer Exclusive Remedies Installation and Maintenance Instructions for Firmware Versions up to and Including V3 1X 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 workman ship 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
2. ER een 20 Section 5 Configuration Parameter Details 27 RED xni TERI UT RIA VERI E Dese hid ea 27 5 2 Point Setup Parameters a c ep akg dee bd aee quate det uas 27 5 3 Miscellaneous Setup Parameters 35 5 4 Temperature Sensor Alarms Configuration 36 5 5 Other Alarms 9 39 5 6 Communications Setup 2 Dad e oe BA 47 5 7 Operator Console Functions 49 Section 6 Monitored Parameter Details 51 6 T Introductio a asso e t ele tdeo eI obe tne 51 6 2 AnalogiReadih s c anna a a UR READER EE aa 51 52 Section 7 Control Modes 54 TA Introduction T 54 7 2 008822 2 ski a dele etta a E 54 7 3 L ad Shedding Gontrol MOde teme E Pha 56 Section 8 Troubleshooting 57 8 1 Operator Checks
3. 10 2 1 Introduction sr rnv E ERIS Me ace DN RE de s 10 2 2 nitial InSpectiol 1x nuntium repre Den pep mic ERR Ra RU womans 10 2 3 Operator Safety 0 0 5 10 2 4 Operating Environmierit AA prt tdt ak k e aval 10 2 5 InstallationiLOcation 10 2 6 Mounting Procedures sacos DAN Qus 11 2A WANING tg bse Sts nie ober Enea RD NES dette Gk edd P ba miedo RU Ie by 11 2 8 Initial PoWer p o tree eco ame AMOR EE RR RODA ER E UNA DDR gs 14 2 9 Setup for the OTO Ea D ed dc retient died a 14 Section 3 Operator Console and 15 3A Alphanurmeric Display 22 et reb Cert e ien epe ape de dtt pos 15 ___ __ _ 3 22 232 lt 6 15 _ 16 I X _ E 16 Section 4 0perator Console Modes 18 I V 18 4 2 Monitor 19 I
4. CONTROL SETPOINT 20 C LOISI 1020 LOLOAD 1 0A HI GFI 50 mA GFITRIP 75mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP END Table 4 9 Misc Setup Sub Menu TEMP UNITS C or F VERSION V3 16 3 EXT INPUT NOT USED INHIBIT or FORCE FLASH ALARM OUTPUT YES or NO ALARM OUTPUT N C or 0 LANGUAGE ENGLISH or FRANCAIS PASSCODE 0000 to 9999 only if 0 or database is unlocked SCROLL DELAY 0 07 to 0 25 5 LOAD DEFAULTS END 25 26 4 3 7 COMMUNICATIONS SETUP SUB MENU The settings found in this sub menu must be configured whenever an optional communica tions board is installed in the Control Module CONTROL SETPOINT 20 C LOTS1 10 C LOLOAD 1 0A HI GFI 50 mA GFITRIP 75 TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP END Table 4 10 Communications Setup PROTOCOL HTCBUS or MODBUS ASCII or MODBUS RTU HTCBUSADDR 1 to 16777215 only if PROTOCOL HTCBUS MODBUS ADDR 1 to 247 only if PROTOCOL HTCBUS MODBUS SUB ADDR 10 31 only if PROTOCOL HTCBUS BAUD RATE AUTO or 9600 or 4800 or 2400 or 1200 or 600 or 300 PARITY NONE or ODD or EVEN only if PROTOCOL HTCBUS HARDWARE NONE OR MODEM OR RS 232 or RS 485 DRIVER AUTO or RS 485 or RS 232 or MODEM PROFILE AUTO or 3 WIRE RS 232
5. NTR 12VD EXTERNAL IN EXTERNA CLOSE INHIBIT 2K MAX CONTACT ACTIVATE ERRIDE M 5 INHIBIT USING ESISTANCE C D910 009 C 5 2 EXTERNAL INHIBIT OVERRIDE USING A DC SIGNAL 910 C NTR 12V0 5VDC 1 10ma MAX 24V IC N MINAL EXTERNAL INP Uu 5 INHIBIT USING EXTE ERRI Al JE INPU DC SIGNAI D910 009 73 Appendix D HTC Load Shedding Sequence Normal mode control Load shedding command received HTC load shed enabled N All other contact inputs active 1 HTC holds its output OFF for 30 seconds Is communications active 2 Control at low temp alarm setpoint Fail safe mode enabled HTC temp All matching HTCs set pid 2n their outputs to OFF a us f HTC display indicates 3 load shedding mode 4 1 If an HTC is associated with more than one contact input 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
6. 5 5 22 SWITCH LIMITING STATUS SSR ONLY Purpose The switch limiting feature is always enabled when using an SSR output switch and is intended to provide protection for the output switch Enabling this alarm will only inform the user that switch limiting is currently active and an excessively high current con dition is present The controller pulses its output switch for a small number of cycles and reads the resulting current If the measured current exceeds the SWITCH RATING setting then the duty cycle of its output switch will be varied so that an average current not exceed ing 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 Note that the SWITCH LIMITING ALARM does not have to be enabled in order to adjust the SWITCH CURRENT RATING setting Notes This is a non latching alarm This alarm should normally be enabled Currents in this range cannot be considered nor mal and should be investigated 5 5 23 CONTACTOR COUNT ALARM 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 pre ventative 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 CONTACT
7. 57 8 2 Common Problem Areas os rte esa dre e ux lene PT i 57 8 3 Common Alarms What to 00 10 60 Section 9 Mairilenance sedere Se edel i reme derum a 63 9 1 Operator Maintenant ae eset obe dece qae d witha bad 63 9 2 63 Appendix A Specifications 64 Appendix B Typical Enclosure Dimensions 65 B 1 Standard Fiberglass EMR Assembly 65 B 2 Optional Stainless Steel EMR Assembly 66 Standard Fiberglass SSR Assembly 67 B 4 Optional Stainless Steel SSR Assembly 68 5 910 Series HTC Control Module Dimensions 69 Appendix C Wiring Diagrams 70 lt 3 lt 332 lt 0060 70 70 6 3 Communications Wiring 22220 eet a hits 71 6 4 Alarm Output Wining as teste Aca agentes tte Re rer A ewig 72 0 5 External Input Output Port Wiring
8. The CONTACTOR CYCLE COUNTER is only indicated if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR 6 3 4 TIME IN USE Purpose The purpose of this feature is to indicate the total hours in use of the controller since its initial operation It may be useful to log the amount of time a particular controller has been in operation 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 Operator Console or a communicating device Note The IN USE hours accumulator value will roll over to zero when the upper limit of the accumulator has been exceeded This limit is 999 999 999 hours 6 3 5 TIME SINCE LAST RESET Purpose This feature indicates the total hours in use of the controller since the last reset It may be useful to log the amount of time a particular controller has been in operation since the last time the controller s power was cycled for trouble shooting purposes Procedure The TIME SINCE LAST RESET hours accumulator can only be reset by cycling the controller s power Note The TIME SINCE LAST RESET will roll over to zero when the upper limit of 65 535 hours has been exceeded 6 3 6 PEAK LOAD CURRENT Note The PEAK LOAD CURRENT is not displayed on the Operator C
9. w TRANSMIT DATA 0 3 WIRE RS 232 PTI 71 C 4 Alarm Output Wiring 72 C 4 1 USED AS A DRY CONTACT 910 CONTROLLER 12VDC s 14 0 DRY CONTACT ALARM RELAY T s 0 COMMON 4d DRY CONTACT C 4 2 USED AS A SWITCHED DC CONTACT 910 CONTROLLER 4 DRY CONTACT 1 ALARM REI Ac Y SWITCHED COMMON EQ IM ALARM POWERED ALARM CONTACT 4 3 USED AS AN AC ALARM RELAY 910 CONTROLLER L1 LINE gt 19 le 0 AC ALARM 0 754 277VAC MAX RELAY T 13 AC ALARM OUTPUT L2 NEUTRAL 00 24 AC ALARM RELAY DRY CONTACT UTPUT C 4 4 Used as a Powered AC Alarm Relay 910 C NTR LLER L1 LINE UT AC A R Le NEUTRAI 5 UT 0 754 277VAC MAX SWITCHED UN ALARM 1 LINE 2 NEUTRAL UT P W ED AC ALARM RELAY C 5 External Input Output Port Wiring C 5 1 EXTERNAL INHIBIT OVERRIDE USING A DRY CONTACT 910 C
10. HI VOLT HI VOLT FILTER LO RESIST LO RESIST LO RESIST FILTER HI RESIST HI RESIST HI RESIST FILTER NOMINAL RESIST OVERCURRENT TRIP SWITCH FAIL HTC RESET C B LIMITING POWER LIMITING SWITCH LIMITING CONTACTOR COUNT CONTACTOR COUNT EEROM DATA FAIL END ENA or DIS 0 3 to 100 0 A 0 to 12 S ENA or DIS 0 3 to 100 0 A 0 TO 12 S ENA or DIS 20 to 250 mA 0 to 12 S ENA or DIS 20 to 250 mA ENA or DIS 10 to 330 V 0 to 12 S ENA or DIS 10 to 330 V 0 to 12 S ENA or DIS 1 to 100 0 to 12 S ENA or DIS 1 To 250 0 to 12 5 2 00 to 2000 00 Q only if LO or HI is enabled ENA or DIS only if SSR is being used ENA or DIS ENA or DIS ENA or DIS only if SSR is being used ENA or DIS only if SSR is being used ENA or DIS only if SSR is being used ENA or DIS only if Deadband or Prop Amb Contactor are being used only if Deadband or Prop Amb Contactor are being used 0 to 999999 ENA or DIS 23 24 4 3 5 POINT SETUP SUB MENU The Point Setup sub menu is used to configure parameters that relate directly to the spe cific control point Included in this menu are control mode settings circuit breaker and switch ratings autocycle set up parameters etc CONTROL SETPOINT 20 C LOWS 1030 LOLOAD 1 0A HI GFI 50 GFITRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT
11. 91 4 92 2 93 4 94 6 95 8 97 1 98 3 99 5 100 8 102 0 103 3 104 6 105 9 107 2 108 5 109 8 111 1 112 5 113 8 115 2 116 5 117 9 119 2 120 6 122 0 123 4 124 8 126 2 127 6 129 0 130 5 131 9 76 73 70 67 65 62 59 56 53 51 48 45 42 40 37 34 31 28 26 23 20 17 15 12 9 6 3 1 10 12 15 18 21 23 26 29 32 35 37 40 43 46 48 51 54 57 60 62 65 F 100 095 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 Ohms 133 4 134 8 136 3 137 8 139 3 140 8 142 3 143 8 145 3 146 8 148 4 149 9 151 5 153 0 154 6 156 2 157 7 159 3 160 9 162 5 164 2 165 8 167 4 169 0 170 7 172 3 174 0 175 7 177 4 179 1 180 8 182 5 184 2 185 9 187 6 189 191 1 192 9 194 5 196 4 198 2 199 9 201 7 203 5 205 3 207 2 109 0 210 8 212 7 214 5 216 4 68 71 73 76 79 82 85 87 90 93 96 98 101 104 107 110 112 115 118 121 123 126 129 132 135 137 140 143 146 148 515 154 157 160 162 165 168 171 173 176 179 182 185 187 190 193 196 198 201 204 207 F 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340
12. 345 350 355 360 365 370 375 380 385 390 395 400 405 Ohms 218 2 220 1 222 0 223 9 225 8 227 7 229 6 231 5 233 5 235 4 237 4 239 3 241 3 243 3 245 3 247 2 249 3 251 2 253 3 255 2 257 3 259 3 261 4 263 4 265 5 267 6 269 6 271 7 273 8 275 9 278 0 280 1 282 3 284 4 286 5 288 6 290 8 293 1 295 2 297 5 299 8 301 4 303 7 306 0 308 3 310 6 312 2 314 5 316 8 319 1 320 6 C 210 212 215 218 221 223 226 229 232 235 237 240 243 246 248 251 254 257 260 262 265 268 271 273 276 279 282 285 287 290 293 296 298 301 304 307 310 312 315 318 321 323 326 329 332 335 337 340 343 346 348 F 410 415 420 425 430 435 440 445 450 455 460 465 470 475 480 485 490 495 500 505 510 515 520 525 530 535 540 545 550 555 560 565 570 575 580 585 590 595 600 605 610 615 620 625 630 635 640 645 650 655 660 Appendix G Factory Default Configuration V3 1X 910 Series HTC BASIC MODE MENU All other parameters are set as shown in the Advanced Mode Sub Menus Configuration Mode Menu Parameter Factory User Control Setpoint 68 F 20 C Lo TS 1 14 F 10 C Lo Load 1 0A Switch Control Mode Deadband Circuit Breaker n a 30 0A Temperature Units SF Feature Mode Basic ADVANCED MODE MENUS Configuration Mode Main Menu Parameter Factory User Control Setpoint 68 F 20 C Lo TS 1 14 F 10 C Lo Load 1 0
13. 50 GFITRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP a Table 4 6 TS Alarms Configuration Sub Menu 5 1 ENA or DIS LOTS1 ENA or DIS LOTS1 60T0570 C HITS 1 ENA or DIS HITS1 60 T0570 C 5 2 ENA or DIS LOTS2 ENA or DIS LOTS2 60T0570 C HITS 2 ENA or DIS HITS2 60 0570 0 LOTS FILTERS 0 to 999 MIN only if LO TS 1 or 2 are enabled HITS FILTERS 1010999 MIN only if HI TS 1 or 2 are enabled LATCH TS ALARMS YES or NO FAIL ENA or DIS END 4 3 4 OTHER ALARMS CONFIG SUB MENU This sub menu allows the user to set up all alarms that do not directly relate to the tempera ture sensors These include all AC alarms voltage current ground fault etc as well as protection settings such as power limiting etc Each alarm may be ENAbled or DlSabled If the alarm is ENAbled an alarm setting and filter setting may be entered CONTROL SETPOINT 20 C LOWS 1030 LOLOAD 1 0A HI GFI 50 GFITRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP ESSEN Table 4 7 Other Alarms Configuration Sub Menu LO LOAD LO LOAD LO LOAD FILTER HI LOAD HI LOAD HI LOAD FILTER HI GFI HI GFI HI GFI FILTER GFI TRIP GFI TRIP LO VOLT LO VOLT LO VOLT FILTER HI VOLT
14. 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 then a data rate of 300 will always be used Otherwise if BAUD RATE AUTO and a non MODEM communication interface is used the PROTOCOL is either MODBUS protocol then a data rate of 9600 is used 5 6 6 PARITY MODBUS Purpose Defines the type of parity bit to be 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 5 6 7 HARDWARE Purpose Identifies the type of communications interface installed in the 910 The controller will automatically determine and display which communications interface type is available Values NONE MODEM or RS 232 or RS 485 5 6 8 DRIVER Purpose Defines the way in which the controller s program communicates with the com munications interface Setting AUTO or RS 232 or RS 485 or MODEM Procedure It is recommended that the setting be set to AUTO this will allow the controller to automatically choose the setting to match the type of communications interface installed 5 6 9 PROFILE Purpose Defines the way in which the controller s program supports communications handshaking and communication interface signals Setting AUTO or 3 WIRE 5 232 or RS 485 or 1200 BAUD MODEM or 300 BAUD MODE
15. 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 filter time has expired 7 2 3 PROPORTIONAL AMBIENT SSR CONTROL FOR USE WITH SSRS ONLY When an HTC using an SSR is 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 SET POINT temperature If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting then power is applied to the trace with a duty cycle of 100 the controller output is fully on If the temperature sensed by the control sensor is equal to or greater than the CONTROL SETPOINT temperature then the output will have a duty cycle of 0 the controller out put 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 Cont
16. Assembly in a Fiberglass Enclosure with Window Model 910 E1FWL EMR2 BACKPLANE 67 B 4 Optional Stainless Steel SSR Assembly 10170 004 68 0 65 r 787 5 31 o 0 3 dia 0 3 dia O 8 453 _ LEFT SIDE VIEW FRONT 2 pole 30A EMR Assembly in a Fiberglass Enclosure with Window Model 910 E1FWL EMR2 IE 0 3 dia BACKPLANE B 5 910 Series HTC Control Module Dimensions Mounting slots suitable for a 8 machine screw 69 Appendix C Wiring Diagrams The following drawings provide sample wiring diagrams for the 910 Series control products and optional accessories Please contact your local Tyco Thermal Controls representative for information regarding other available options C 1 TS Wiring SHIELD 195 DRAIN SOURCE 20 WHT RTD 1 SENSE 21 WHT 100n I Pt RTD SHIELD 8 w DRAIN SOURCE 9 WHT RTD 2 SENSE 106 WHT 100 CiM A Ren Pt
17. Nema 4X IP65 SS Type 304 Nema 4X IP65 2 pole switching 30 A continuous 40 C derate linearly to 15 A max 60 C resistive load 100 277 Vac nom max 80 A 1 sec in rush 625 A 1 cycle in rush 2 pole switching 30 A continuous 40 C derate linearly to 20 A max 60 C 100 277 Vac nom max 40 F to 140 F 40 C to 60 C 100 to 277 Vac nom 1PH 50 60 Hz 0 2A max 0 75A Aux AC output terminals 12Vdc nom 250ma max Proportional Deadband Proportional Ambient SSR Proportional Ambient Contactor modes Adjustable 2 F to 90 F 1 C to 50 C 2 RTD inputs 3 wire 100Q Platinum DIN 43760 0 0 003850 0 or 2 3 wire 1000 Ni Fe open shorted sensor detection protection lead resistance compensated 0 to 200 per lead 76 F to 1058 F 60 C to 570 C accuracy 0 5 of span 1LSD 80 to 295Vac accuracy 1 of span 2LSD repeatability 1 5 of span 0 3 to 100A resolution 0 1A 0 3A to 11A range 0 3A 11A to 40A range 0 7A 40A to 100A range accuracy 2 5 of reading resolution 20 to 250ma accuracy 2 5 of span 2LSD at nominal load repeatability 4 of span 48Vac dc 500ma 10VA switching max 0 75A 100 277 Vac nom max Appendix B Typical Enclosure Dimensions The following drawings provide the user with enclosure size and mounting dimensions for the stock 910 enclosure assemblies Please contact your local Tyco Thermal Con
18. RESIS TANCE 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 NOMINAL RESISTANCE setting 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 temperature which in turn is affected by ambient temperature insulation level a full or empty pipe or vessel etc 5 5 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 using a technique involving measured in rush current and the SWITCH CURRENT RATING If the controller is unable to start the cable it will eventually trip its output
19. SETUP MISC SETUP COMMUNICATIONS SETUP EXER Table 4 8 Point Setup Sub Menu TAG 19 ALPHANUMERIC CHARACTERS SWITCH CONTROL MODE PROPORTIONAL PROP AMB SSR DEADBAND PROP AMB CONTACTOR DEADBAND 1 to 50 C only if SWITCH CONTROL MODE is DEADBAND PROP BAND 1 to 50 C only if SWITCH CONTROL MODE is not DEADBAND CYCLE TIME 10to255 MIN only if SWITCH CONTROL MODE is not PROP AMB CONTACTOR SWITCH RATING 0 3 100 0 only if SSR is being used CIRCUIT BREAKER 0 3 100 00 A only if SSR is being used POWER 3 Wto 33 000 W only if SSR is being used 5 FAIL MODE OFF or ON TSCTLMODE TS 1 FAIL OFF ON TS 1 FAIL TO TS 2 or TS 2 FAIL OFF ON or TS 2 FAIL TO TS 1 or AVERAGE FAIL OFF ON or AVERAGE FAIL TO GOOD or LOWEST FAIL OFF ON or LOWEST FAIL TO GOOD TS1TYPE 1100 PLAT or NI FE TS 1 LEAD RESIST 1 to 20 000 Q only if TS 1 TYPE NI FE TS1HILIMIT ENA or DIS TS2TYPE 1100 PLAT or NI FE TS 2 LEAD RESIST 070 20 000 Q only if TS 2 TYPE NI FE TS2HILIMIT ENA or DIS AUTO CYCLE ENA or DIS AUTO CYCLE INTERVAL 1110240 only if AUTO CYCLE ENA AUTO CYCLE UNITS HOURS or MINUTES only if AUTO CYCLE ENA OVERRIDE SOURCE REMOTE or EXT INPUT LOAD SHEDDING ENA DIS END 4 3 6 MISC SETUP SUB MENU The Misc Setup sub menu is used to configure miscellaneous parameters
20. close to normal operating current 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 8 3 6 LOW CURRENT This alarms current levels which are less than the LOW CURRENT ALARM setting Cause of Alarm 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 8 3 7 HIGH GFI This alarms ground fault current levels which are greater than the HIGH GFI ALARM setting Cause of Alarm Alarm setting too close to normal leakage current Damaged cable insulation and or moisture present Moisture in junction box Poor splice or termination Moisture provides conductive ground path which allows ground fault current 8 3 8 GFI TRIP This value sets the upper limit of allowable ground fault leakage Exceeding this limit will result in the output switch being latched off and the alarm activated to indicate a ground fault condition Cause of Alarm Trip setting too close to normal leakage current Damaged cable insulation and or moisture present e Moisture in junction box Poor splice or termination Moisture provides conductive ground path which allows ground fault current 8 3 9 HIGH VOLTAGE This alarms voltage levels that are greater than the HIGH VOLTAGE ALARM setting Cause of Ala
21. device such as the Model 780 GCC 9000 See the 780 GCC 9000 user manual for the prop er procedure Note The CONSOLE SETPOINT MAXIMUM is not displayed on the Operator Console 5 2 24 CONSOLE SETPOINT MINIMUM Purpose When using the Operator Console the minimum setting of the CONTROL SET POINT 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 temper ature setting to a dangerous level Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the CONSOLE SETPOINT MINIMUM temperature value to limit the mini mum allowable CONTROL SETPOINT TEMPERATURE that may be set using the 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 Note The CONSOLE SETPOINT MINIMUM is not displayed on the Operator Console 5 3 Miscellaneous Setup Parameters The following section describes miscellaneous the setup parameters 5 3 1 TEMPERATURE DISPLAY UNITS Purpose This allows selection of the type of temperature units to display on the 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 Communications Controller The GCC may be set independently Setting DEGREES F or DEGREES C Procedure Ad
22. from the input terminals Connect a 100 Q resistor across the source or sense terminal and common Insert a jumper between the source and sense terminals Apply power to the controller The indicated or displayed temperature should be about 32 F 0 C 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 con troller however a bouncing temperature of a few degrees should not be confused with incorrect operation 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 only 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 extend ed 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 insulation rating equal to or greater than the highest voltage in the conduit Follow the proper Electrical Code requirements for
23. hot product Steaming out lines Incorrect tracer wiring 8 3 2 LOW TS 1 TS 2 TEMPERATURE This alarm appears when the temperature decreases below the LOW TS ALARM tempera ture setting Cause of Alarm Alarm temperature setting too close to maintain temperature Flow of cold product Empty pipe Damaged wet or missing insulation e Heating cable not sized properly for the application 8 3 3 TS 1 TS 2 FAILURE This alarm indicates a sensor is not operating properly The temperature sensor may fail due to an open or shorted condition Cause of Alarm 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 8 3 4 CONTROL TS FAILURE This 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 CON TROL MODE the output switch may be latched off or on until this failure is corrected Cause of Alarm 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 e Damaged or inoperative temperature sensors 8 3 5 HIGH CURRENT This alarms current levels that are greater than the HIGH CURRENT ALARM setting for the application Cause of Alarm Alarm setting too
24. indicated again until the entire alarm filter time has expired 5 4 8 HIGH TEMPERATURE SENSOR ALARM FILTER TIME SETTING 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 f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 Other Alarms Configuration The HIGH TS ALARM FILTER time setting will not affect the cutout time when the HIGH LIMIT CUTOUT feature is enabled 5 4 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 NON LATCHING P
25. is damaged it should be kept until the contents of the shipment have been verified for com pleteness and the equipment has been checked mechanically and electrically Procedures for configuring and operating the heat trace controller are given in Sections 111 IV and V If the shipment is incomplete there is mechanical damage a defect or the controller does not pass the electrical performance tests notify the nearest Tyco Thermal Controls representa tive 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 910 controller using solid state relays is suitable for Class 1 Division 2 Groups A B C and D hazardous areas Hazardous areas are defined by Article 500 of the National Electrical Code and Section 18 of the Canadian Electrical Code Electromechanical relay EMR based assemblies are suitable for use in ordinary non hazardous areas only Caution Some 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 specified in the 910 Heat Trace Controller Specifications outlined in Appendix A The wide ambient operating temperature range of the controller permits installation in most any convenient location Conside
26. 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 consumed 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 combination 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 com pletely 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 out put should be approximately 50 Setting 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 5 2 5 DEADBAND SETTING Deadband control mode only Purpose When an HTC equipped with a contactor is used to
27. related to time I t and adjusts the output duty cycle accordingly limiting the amount of current to an acceptable level Range 0 3 to 100 0 Amps Procedure Adjust the CIRCUIT BREAKER CURRENT RATING setting to the heating circuit breaker size i e 30 0 Amps Note This feature should NOT be used to reduce the size of a circuit breaker or increase the maximum heating cable length It can be quite effective in preventing nuisance trips due to incorrect design or factors outside those considered by the design 5 2 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 cur rent to an appropriate level The MAXIMUM POWER level may be adjusted to eliminate step down transformers lower the effective output wattage of a cable or implement energy management of the heat trace circuit Range 3 to 33 000 Watts 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 Do not set the MAXIMUM POWER below full outpu
28. supervisory software are interrupted or if the power has been reset to the HTC the HTC will hold its output OFF waiting for a Load Shedding command 3 Only if the Low Temperature Alarm is ENABLED 4 For 910 Series controllers a lt Load Shedding gt message will displayed after the load current reading 74 Appendix E 100 Platinum RTD Table DIN 43760 100 Q Platinum Resistance Temperature RTD 0 00385 Ohms Ohm C Ohms C F Ohms F Ohms C F 60 25 100 148 159 18 155 311 250 48 410 770 62 28 95 139 161 04 160 320 252 19 415 779 6430 90 130 162 90 165 329 253 90 420 788 66 31 85 121 164 76 170 338 255 61 425 797 68 3 80 112 166 61 175 347 257 32 430 806 7053 75 103 168 46 180 356 259 02 435 815 72 33 70 94 170 31 185 365 260 72 440 824 74 33 65 85 172 16 190 374 262 42 445 833 76 33 60 76 174 00 195 383 264 11 450 842 78 32 95 67 175 84 200 392 265 80 455 851 80 31 50 58 177 68 205 401 267 49 460 860 82 3 45 49 179 51 210 410 269 18 465 869 8427 40 40 181 34 215 419 270 86 470 878 8625 35 31 183 17 220 428 272 54 475 887 88 22 30 22 184 99 225 437 274 22 480 896 90 19 25 13 186 82 230 445 275 89 485 905 92 16 20 4 188 63 235 455 277 56 490 914 9412 15 5 190 45 240 464 279 23 495 923 96 09 10 14 192 26 245 473 280 90 500 932 98 04 5 23 194 07 250 482 282 56 505 941 100 0 0 32 195 88 255 491 284 22 510 950 101 95 5 41 197 69 260 500 285 87 515 959 103 90 10 5
29. your particular installation Terminal connections that are not tight can add resistance to an RTD circuit Check the tightness of all screw terminal connections at time of installation and during subsequent maintenance checks 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 off set between what the controller reads and what the RTD actually measures This again is normally not a problem since the controller compensates for all but the worst cases of this Lastly it is 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 8 2 2 GROUND FAULT Ground fault alarms can be due to incorrect installation as well as leakage resulting from wet system components or faulted cables The 910 Series Controller 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 t
30. 0 199 49 265 509 287 53 520 968 105 85 15 59 201 29 270 518 289 18 525 977 107 79 20 68 203 08 275 527 290 83 530 986 109 73 25 77 204 88 280 536 292 47 535 995 111 67 30 86 206 67 285 545 294 11 540 1004 113 61 35 95 208 45 490 554 295 75 545 1013 115 54 40 104 210 24 295 563 297 39 550 1022 117 47 45 113 212 02 300 572 299 02 555 1031 119 40 50 122 213 80 305 581 300 65 560 1040 121 32 55 131 215 57 310 590 302 28 565 1049 123 24 60 140 217 35 315 599 303 91 570 1058 125 16 65 149 219 12 320 608 305 53 575 1067 127 07 70 158 220 88 325 617 307 15 580 1076 128 98 75 167 222 65 330 626 308 76 585 1085 130 89 80 176 224 41 335 635 310 38 590 1094 132 80 85 185 226 17 340 644 311 99 595 1103 134 70 90 194 227 92 345 653 313 59 600 1112 136 60 95 203 229 67 350 662 315 20 605 1121 138 50 100 212 231 42 355 671 316 80 610 1130 140 39 105 221 233 17 360 680 318 4 615 1139 142 20 110 230 234 91 365 689 319 99 620 1148 14417 115 239 236 65 370 698 321 59 625 1157 146 06 120 248 238 39 375 707 323 18 630 1166 147 94 125 257 240 13 380 716 324 76 635 1175 149 82 130 266 241 86 385 725 326 35 640 1184 151 70 135 275 243 59 390 734 327 93 645 1193 153 58 140 284 245 31 395 743 329 51 650 1202 155 45 145 293 247 04 400 752 331 08 655 1211 157 31 150 302 248 76 405 761 332 66 660 1220 Appendix F 100 Nickel Iron RTD Table Ohms 69 8 714 72 3 731 74 3 75 5 76 7 78 0 78 8 80 0 81 2 82 2 82 9 84 2 85 7 86 9 88 1 88 9 90 1
31. 100 to 277 Vac circuit The wiring termi nal assignments are defined below Power Connections Terminal No Line L1 power input A Neutral L2 power input B Line L1 output to trace C Neutral L2 output to trace D Wiring diagrams for typical configurations are included in Appendix C 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 Caution Before applying power to the controller ensure that powering the circuit will not damage 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 910 has been suitably programmed for correct and safe operation 2 8 1 INITIAL CABLE TEST To minimize the risk of damage to the controller due to a cable fault the integrity of the heating cable should be verified by 1 Performing a high voltage insulation test using a Megger 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 910 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 t
32. 2 Monitor Mode Main Menu CONTROL MODE TS 1 TEMP TS 2 TEMP LOAD RESIST GFI VOLT POWER TEST TRACING DISPLAY TEST MAINTENANCE DATA END 4 C 4 C 7 8 9A 13 26 Q 0 mA 118V 1050W only if TS2 is being used or POWER 10 4 kW Turn on tracing for 30 seconds To abort DISPLAY TEST press any key Note the indicating a sub menu 4 2 2 MAINTENANCE DATA SUB MENU This sub menu is used to view minimum and maximum temperatures total accumulated power hours in use and the number of hours since the last time the Controller was reset 4 3 Configure Mode 20 These parameters may be reset by the user CONTROL TEMP 4 C TS 1 4C 5 2 7 LOAD 8 9A RESIST 13 26 Q GFI 0 mA VOLT 118V POWER 1050 W TEST TRACING DISPLAY TEST MAINTENANCE DATA END Table 4 3 Maintenance Data Sub Menu MINCTLTEMP 2 C MAXCTLTEMP 65 C TS1MINTEMP 2 C TS1MAXTEMP 65 C TS2MINTEMP 1 C TS2MAXTEMP 61 C POWER ACCUM 145 9 kW h CONTACTOR CYCLE COUNT 1234 only if Deadband or Prop Amb Contactor modes are being used INUSE 2896h TIME SINCE LAST RESET 675 END The Configure mode is selected when the operator presses the SHIFT key followed by the CONFIG key This mode allows you to examine or alter the Controller s configuration There are two types of configuration modes each presenting differ
33. 873 Previously Pyrotenax doc 20276008 Printed in U S A 2002 Tyco Thermal Controls LLC
34. A Hi GFI 20 mA GFI Trip 30 mA Feature Mode Advanced TS Alarms Configuration Sub Menu Parameter Factory User TS 1 Fail Enable Lo TS 1 Enable Lo TS 1 14 F 10 C Hi TS 1 Disable Hi TS 1 n a 212 F 100 C TS 2 Fail Disable Lo TS 2 Disable Lo TS 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 0 min Latch TS Alarms Yes CTL TS Fail Enable 77 78 Other Alarms Configuration Sub Menu Parameter Lo Load Lo Load Lo Load Filter Hi Load Hi Load Hi Load Filter Hi GFI Hi GFI Hi GFI Filter GFI Trip GFI Trip Lo Volt Lo Volt Lo Volt Filter Hi Volt Hi Volt Hi Volt Filter Lo Resist Lo Resist Lo Resist Filter Hi Resist Hi Resist Hi Resist Filter Nominal Resist Overcurrent Trip Switch Fail HTC Reset C B Limiting Power Limiting Switch Limiting Contactor Count Contactor Count EEROM Data Fail Factory User Enable 1 0A 0 sec Disable n a 30 0A n a 0 sec Enable 20 mA 0 sec Enable 30 mA Enable 90 V 0 sec Disable n a 270V n a 0 sec Disable n a 50 n a 0 sec Disable n a 50 n a 0 sec 6 00 Q n a Enable Enable Disable n a Disable n a Disable n a Disable Enable 200 000 Enable Point Setup Sub Menu Parameter Factory User Tag TAG factory ID Switch Control Mode Deadband Prop Band n a 4 F 2 C Deadband 5 F 3 C Cycl
35. A 277 V SSR Controls a single circuit with a 2 pole solid state relay Includes an isolated 2 wire RS 485 communication option Approved for Class I Div 2 areas DigiTrace DigiTrace Supervisor Software DigiTrace 910 controller in an 8 x 10 stainless steel enclosure with window DigiTrace Supervisor 10391 002 DIGITRACE 910 CONTROLLERS MADE TO ORDER Contact factory for lead time 910 E1SW EMR2 10170 003 2 pole 30 A EMR Controls a single circuit with a 2 pole electromechanical relay Approved for ordinary areas only DigiTrace 910 controller in an 8 x 10 stainless steel enclosure with window 910 E1SW EMR2 485 10170 017 2 pole 30 A EMR Controls a single circuit with a 2 pole electromechanical relay Includes an isolated 2 wire RS 485 communication option Approved for ordinary areas only DigiTrace 910 controller in an 8 x 10 stainless steel enclosure with window 910 E1SW SSR2 10170 004 2 pole 30 A 277 V SSR Controls a single circuit with a 2 pole solid state relay Approved for Class I Div 2 areas DigiTrace 910 controller in an 8 x 10 stainless steel enclosure with window 910 E1SW SSR2 485 10170 018 2 pole 30 A 277 V SSR Controls a single circuit with a 2 pole electromechanical relay Includes an isolated 2 wire RS 485 communication option Approved for Class I Div 2 areas RTD ambient cable style C1D1 RTD 100 F to 900 F pipe mounted RTD 100 to 900 F pipe mounted RT
36. D SENSORS 100 ohm platinum RTD with 10 stainless steel corrugated sheath OPTIONS RTD10CS RTD10CS MONI RTD 200 254741 RTD7AL RTD7AL RTD4AL RTD4AL Weight 15 15 20 20 20 20 25 25 1 0 0 1 2 0 1 2 Append the following code s to the end of the standard Model Code to have the option included at the factory Option Code 232 MDM ALR ALG Description RS 232 communications option replace 485 with 232 Modem communications option replace 485 with MDM Red LED pilot light Green LED pilot light Contact your local representative for configurations not listed here Section 2 Installation and Wiring A 2 1 Introduction 2 2 Initial Inspection 2 3 Operator Safety Considerations 2 4 Operating Environment 2 5 Installation Location 10 Caution Be sure all personnel involved in installation servicing and programming are qual ified 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 regarding the initial inspection preparation for use and storage instructions for the 910 Series Heat Trace Controller Inspect the shipping container for damage If the shipping container or cushioning material
37. DEM communication interface is used 5 6 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 stabi lize 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 required 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 con junction with the Operator Console 5 7 1 PASSCODE Purpose The four digit numeric PASSCODE feature stops unauthorized users from modify ing the controller s configuration parameters using the Operator Console Range 0000 to 9999 Procedure Enter the desired PASSCODE in the Miscellaneous Common Setup sub menu using the Operator Console keypad A PASSCODE of 0000 disables the lockout fea ture and allows all configuration parameters to be modified using the 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 parameters using the Operator Console Note The PASSCOD
38. DigiTrace 910 Series Heat Trace Controller Installation Operating and Maintenance Instructions Firmware versions up to V3 1X Document H56873 Please read all instructional literature carefully and thoroughly before starting N 6 DigiTrace T Trl Ei ii jejejeje II LI LI Tyco Thermal Controls TABLE OF CONTENTS 4 4 Warranty Exclusion Disclaimer 4 Excl sive Remedies 4 Conducted and Radiated Emissions 5 Section 1 Overview os oii nih epe fpe ed 6 6 1 2 Controllers Covered by this 6 1 9 Product OVeLVIBW VE DE ar ede eed 6 1 4 Modular Compong 2 eo ene oeste ete bd taped ed 8 8 1 6 Ordering and Configuration Guide 9 Section 2 Installation and
39. E can be edited only if it is set to 0 or the database has been unlocked by entering the proper PASSCODE 5 7 2 LOCK DATABASE Purpose If the PASSCODE has 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 program ming has been completed 49 50 Procedure Select the LOCK DATABASE function at the end of the Configuration Mode Main Menu to lock out Operator Console configuration modification access The display will confirm the operation by displaying a DATABASE LOCKED message Note Operator Console configuration modification access will automatically re lock after approximately 5 minutes of keypad inactivity 5 7 3 UNLOCK DATABASE Purpose If a PASSCODE has been enabled PASSCODE is not set to 0 and the user wants to modify any of the controller s configuration parameters using a the Operator Console then 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 and a prompt for the PASS CODE will appear If the correct PASSCODE is entered then the display will confirm the oper ation by displaying a DATABASE UNLOCKED message 5 7 4 TEST TRACING Purpose The TEST TRACING feature provides an easy method of temporarily overr
40. EMPERATURE 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 Shield 19 TS 1 Source WHT 20 TS 1 Sense WHT 21 TS 1 Common RED 22 Shield 8 TS 2 Source WHT 9 TS 2 Sense WHT 10 TS 2 Common RED 11 2 7 2 ALARM RELAY CONNECTIONS Two types of alarm relays are provided one is a programmable dry contact output relay and the other is a line voltage AC relay Triac Both may be programmed for N O N C steady or flashing operation and are typically used to annunciate an alarm to an external device such as a DCS PLC etc Notes Both alarm relays are controlled by the 910 using the same signal The N O N C and flashing parameter settings affect both the dry contact and the AC alarm relays The dry contact 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 applica tion stays within the ratings of the relay contacts as defined in Appendix A The AC alarm relay alarm relay is typically used to drive a local external line voltage pilot light etc Refer to the wiring diagrams in Appendix C for example connection details Dry Contact Alarm and Control Sig
41. ENT 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 f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 3 HIGH LOAD CURRENT ALARM Purpose Alarms current levels which are higher than a preset limit for the application Alarm Mask ENABLE or DISABLE Range 0 3 to 100 0 Amps Procedure Adjust the HIGH CURRENT ALARM level to the desired value Note that the HIGH CURRENT ALARM must be enabled in order to adjust the HIGH CURRENT ALARM level Note As the HTC automatically protects itself from overload it would not normally be nec essary to enable this alarm This automatic protection can be used effectively to guard against accidental paralleling of heating circuits In rush or cold start currents typically associated with self regulating cables may cause nuisance HIG
42. ERATURE 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 temperature sensor connected to the TS 1 input 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 5 4 2 LOW TEMPERATURE SENSOR 1 ALARM Purpose If enabled the LOW TS 1 ALARM allows for alarming of low temperature condi tions 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 tem perature 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 con troller for non latching temperature alarms This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT temperature if fail safe mode uses the temperature reading from TS 1 5 4 3 HIGH TEMPERATURE SENSOR 1 ALARM Purpos
43. H CURRENT ALARMS If this is undesirable this alarm should be disabled 5 5 4 HIGH LOAD CURRENT ALARM FILTER TIME SETTING 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 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 f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 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 5 5 6 HIGH GROUND FAULT CURRENT ALARM FILTER TIME SETTING Purpose The HIGH GFI ALARM FILTER will prevent HIGH GFI ALARMS from being indicat ed until a high GFI condition has exi
44. H TS 2 ALARM tem perature setpoint unless the TS 2 high limit cutout feature is enabled Note If no second sensor is installed this alarm should be disabled This alarm may be used for applications 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 alarm ing 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 5 5 18 for more information 5 4 7 LOW TEMPERATURE SENSOR ALARM FILTER TIME SETTING 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 Notes e f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be
45. IFT key this key switches the console to the Alarm mode Exits the current menu or cancels the new setting when editing a parameter Moves the cursor to the left when editing an alphanumeric parameter When prefixed by the SHIFT key this key switches the console to the Monitor mode Selects the item in the display or accepts the setting when editing a parameter Moves the cursor to the right when editing an alphanumeric parameter When prefixed by the SHIFT key this key switches the console to the Configure mode Moves to the previous item in a menu Increments the value when editing Moves to the next item in a menu Decrements the value when editing TM DigiTrace STATUS I ALARM MONITOR CONFIG OUTPUT 3 3 LED Indicators 3 4 Operational Basics 16 The console includes eight LED indicators Four LEDs indicate the console operating mode SHIFTed function ALARM MONITOR or CONFIGure modes There are two status LEDs which indicate the alarm and control output status of the controller 1 The output LED when illuminated steadily indicates that the output of the controller is turned on and is allowing current to flow into the loadtrace circuit For SSR versions pro grammed for proportional modes a flashing LED indicates that the controller is pulsing its output on and off to maintain the setpoint temperature and or control the average amount of current power t
46. 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 51 6 3 Maintenance Data 52 6 2 7 VOLTAGE Purpose The voltage reading indicates the average circuit voltage being measured by the 910 6 2 8 POWER Purpose Load power provides an indication of the average power being consumed by the heat trace cable Note The controller calculates load power by multiplying the average adjusted voltage read ing by the average adjusted current reading 6 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 recorded by the HTC since the last time the values were reset It may be useful to log the maximum mini mum temperatures experienced on a particular tracing circuit for the purposes of trou bleshooting or gathering data for future design criteria The temperature values are written to the controller s non volatile memory once every 24 hours or whenever any maintenance data is reset by the user Max min temperatures are recorded for TS 1 TS 2 and the CON TROL TS Range Can only be reset cleared by the operator Procedure The max min temperatures may be reset using the Operator Console or a com municating device Resetting any
47. M Procedure Select the PROFILE to be compatible with other devices that will be connected to the controller for communications purposes It is recommended that the setting be set to AUTO The controller will automatically select a profile based on the type of communica 5 7 Operator Console Functions tions interface installed in the 910 Notes AUTO Selects a communications profile based on the data rate and the type of communi cations interface installed in the 910 3 WIRE RS 232 Continuously asserts the internal RTS signal Internal CTS and DCD sig nals are ignored The Tx Delay timer is active This is the profile used when PROFILE AUTO and an RS 232 communication interface is used with the 910 RS 485 Uses the internal RTS signal and the Tx Delay timer Internal CTS and DCD sig nals are ignored This is the profile used when PROFILE AUTO and an RS 485 commu nication interface is used 1200 BAUD MODEM Uses the internal RTS signal with a fixed 10 msec Tx Delay time ignores the internal CTS signal Uses the internal DCD signal to qualify each receive data character This is the profile used when PROFILE AUTO BAUD RATE 1200 and a MODEM communication interface is used 300 BAUD MODEM Uses the internal RTS signal with a fixed 30 msec Tx Delay time ignores the internal CTS signal uses the internal DCD signal to qualify each receive data character This is the profile used when PROFILE AUTO BAUD RATE is not 1200 and a MO
48. NTROL SETPOINT temperature This is the primary control mode If either sensor should fail the controller will transfer control to the remaining good sensor and generate the appropriate TS 1 or TS 2 FAILURE ALARM assuming that the alarm is enabled The temperature will now be main tained 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 Note Ensure that TS FAILURE ALARMS are enabled See Sections 5 4 1 5 4 4 and 5 4 10 for a complete explanation of RTD failure detection in the HTC 5 2 12 TS 1 TYPE Purpose This parameter specifies the type of RTD that is connected to the HTC s TS 1 input Setting 3 wire 100 Q Platinum or 2 or 3 wire 100 Q Nickel Iron NI FE Procedure Select the type of RTD that is connected to the TS 1 input Note If a 2 wire 100 O Nickel Iron NI FE RTD is selected then the TS 1 LEAD RESIS TANCE must be entered manually see Section 5 2 13 5 2 13 TS 1 LEAD RESISTANCE 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 va
49. OR ALARM setting to the desired value Note that the CON TACTOR ALARM must be enabled in order to adjust the CONTACTOR ALARM setting Note The CONTACTOR ALARM is only available if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR 5 6 Communications Setup 5 5 24 EEROM DATA FAILURE ALARM Purpose The EEROM DATA FAILURE ALARM indicates 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 gener ated if the microprocessor cannot bypass the failed area of its memory This indicates an internal problem and the 910 should be replaced and returned to the factory for repair The following section describes the setup parameters that relate to the way in which the controller is to communicate with another device If the optional communications interface is not installed in the 910 Control Module these parameters need not be configured 5 6 1 PROTOCOL Purpose Defines the communications language used by the controller to communicate with other devices Setting HTCBUS or MODBUS ASCII or MODBUS RTU Procedure Select the HTCBUS protocol when communicating with existing Pyrotenax Heat Trace Control products incl
50. RTD 5 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 2 7 1 and 8 2 1 for additional details Lead Wire Lead Wire Lead Wire Signal Description Color Scheme 1 Color Scheme 2 Color Scheme 3 IEC 751 Source White White Red Sense White Black Red Common Red Red White C 2 Power Wiring 910 CONTROLLER L1 LIMC INPUT Ab EN e 1PH INPUT POWER Le NeUTRAL INPUT B LE NEUTRAL 100 277 VAC nom 50 60Hz gt LOAD L1 IM DUT SE ww TRACERCS LOAD L2 NEUTRAL PA E NEUTRAL 70 C 3 Communication Wiring 6 3 1 2 WIRE MODEM OPTION 910 C 5 LLER GR UND 18 OA MODEM m M DEM Q DRAIN DE M PTI 6 3 2 2 WIRE RS 485 OPTION 910 C NTR ER 5 5 GR UND DATA DATA DRAIN e WIRE R 5 485 3 3 RS 232 OPTION 910 C NTROLLER 5 M A GR UND 16 17 18 RECEIVE DATA Q
51. TS 2 or a combination of the two temperatures See Section 5 2 11 of this manual for further details regarding the T5 CONTROL MODE settings 6 2 2 TS 1 TEMPERATURE Purpose This temperature is the value that the controller is reading from the RTD connect ed to its TS 1 input Depending on the T5 CONTROL MODE it may be used to determine the CONTROL TEMPERATURE see Section 6 2 1 above Note If the TS 1 input is not being used by the controller the TS 1 TEMPERATURE is not displayed 6 2 3 TS 2 TEMPERATURE Purpose This temperature is the value that the controller is reading from the RTD connect ed to its TS 2 input Depending on the T5 CONTROL MODE it may be used to determine the CONTROL TEMPERATURE see Section 6 2 1 above Note If the TS 2 input is not being used then by the controller then the TS 2 TEMPERA TURE is not displayed 6 2 4 LOAD CURRENT Purpose The LOAD CURRENT reading indicates the average current being drawn by the heating cable 6 2 5 RESISTANCE Purpose Resistance is calculated using the average adjusted voltage reading divided by the average adjusted current reading to yield a load resistance in ohms If the controller s out put 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 always display the last resistance which was calculated while the output switch was last on 6 2 6 GROUND FAULT CURRENT Purpose
52. TYCO THERMAL CONTROLS 300 Constitution Drive Menlo Park California 94025 1164 USA Phone 800 545 6258 Fax 800 596 5004 info tycothermal com www tycothermal com Important 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 oblig ations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product and in no case will Tyco Thermal Controls or its distributors be liable for any incidental indirect or consequential 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 compliance with any applicable specification Tyco and DigiTrace are trademarks of Tyco Thermal Controls LLC or its affiliates CANADA LATIN AMERICA TYCO THERMAL CONTROLS TYCO THERMAL CONTROLS 250 West Street Carlos Calvo 2560 Trenton Ontario C1230AAP Canada K8V 552 Buenos Aires Argentina Phone 800 545 6258 Phone 54 11 4 308 6444 Fax 800 596 5004 Fax 54 11 4 308 6445 Flow Control 12 02 H56
53. ally using the terminal block provided at the terminal board Note Some manufacturers use the common Black White Red triad color code for the RTD connections Usually the RED lead is the common connection same as the White White Red color scheme and the White and Black connections may be used interchangeably 2 Seemingly Incorrect 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 THE POWER TO THE CONTROLLER OFF BEFORE PROCEEDING Disconnect the RTD wiring from the input terminals To calculate 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 mea sured between source and sense This will give a compensated resistance value that can be cross referenced to one of the RTD tables found in Appendix E or Appendix F 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 accu racy standards of the HTC and the RTD Notes Ensure you refer to the correct RTD table for the type of RTD you are using Ensure that the TS TYPE setting matches the type of RTD that you are using To verify the Controller TURN THE POWER TO THE CONTROLLER OFF BEFORE PROCEEDING Disconnect the RTD wiring
54. ange it with another controller This may require some reprogramming of the new HTC Refer to the following sections for the appropriate topic If the fault clears exchange the controller on another circuit to determine if the fault moves with the controller If the fault moves with the controller verify that the HTC has been con figured correctly for the application If the configuration is correct it may be necessary to return the controller to Tyco Thermal Controls for evaluation 8 1 1 GETTING STARTED In order to access the functions of the 910 Series HTC use the Operator Console If the modem communications option is installed in the 910 the Model 780 GCC 9000 Group Communications Controller may also be used to access controller parameters Refer to the GCC User Manual for operational details The HTC may 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 symp toms and parameters to check to determine the actual faulty portion of the heat trace circuit 57 58 8 2 1 RTDS RTD failures after installation can generally be attributed to incorrect wiring or improper installation of the sensor Troubleshooting of these failures is a very simple procedure if the proper steps are undertaken in the correct order Some specific RTD problems and the cor rect methods for troubleshooting are outlined as follows 1 TS Failure Alarm
55. as detected a failure in its nonvolatile memory this is where all of the controller s configuration and calibration settings are stored This indi cates an internal problem and the HTC should be replaced and returned to the factory for repair Cause of Alarm The HTC cannot bypass the failed area of its memory and has loaded factory defaults into this failed area 8 3 20 CONTACTOR COUNT This alarm indicates that the number of off to on transitions of a contactor has exceeded the CONTACTOR COUNT ALARM setting and the contactor should be replaced Cause of Alarm Contactor has been controlling the trace circuit for a long time Some configuration parameter i e DEADBAND AUTO CYCLE INTERVAL load shedding etc is causing the contactor to toggle more than usual The 910 series controller is designed to be a maintenance free product Once installed prop erly the only maintenance required is retightening of the terminal connections approximate ly one week after installation and inspection periodically thereafter Also alarm pilot lamps if installed may need periodic replacement EMR versions may require periodic contactor replacement Caution Make sure that the power to the controller is OFF when replacing the pilot lamps Also be certain power is OFF to the controller before attempting to test or service the heat tracing Do not rely on the controller as a disconnect device There are no user serviceable parts in the 910 series c
56. at is applied to the trace circuit to the C B CURRENT RATING setting to protect the upstream heater circuit breaker from tripping Cause of Alarm Excessive current caused by in rush current C B CURRENT RATING setting too low for normal heater current draw or not matched to actual circuit breaker size 8 3 16 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 Cause of Alarm Excessive current caused by in rush current Excessive ambient temperature 8 3 17 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 Cause of Alarm Alarm setting too close to actual operating resistance NOMINAL RESISTANCE not set properly Open connection wiring problem Damaged cable 8 3 18 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 Cause of Alarm Alarm setting too close to actual operating resistance NOMINAL RESISTANCE not set properly Partial short wiring problem Damaged cable Section 9 Maintenance 9 1 Operator Maintenance 9 2 Replaceable Parts 8 3 19 EEROM DATA FAILURE This alarm indicates that the controller h
57. ck to a centrally located electrical distribution center The 910 Series controller is made up of two components Each component s primary func tion is described below 1 4 1 CONTROL MODULE The 910 Control Module forms the heart of a single heat trace control solution Each Control Module provides all of the intelligence required to control and monitor one heat trace circuit It includes indicators for alarm and output status and an integral Operator Console An inter nal connector is provided to plug in an optional communications interface The Control Module packaging provides a rugged vibration proof design Temperature sensor communications and alarm control wiring are connected to the lever operated spring terminals providing gas tight vibration resistant connections A large easy to read alphanumeric display and menu driven interface eases controller con figuration and eliminates the need for an external programmer Access is available for all monitored parameters programmed values and alarm information Enhanced security is provided by password protection Single phase current monitoring ground fault detection and voltage monitoring are provid ed The 910 Control Module also incorporates a universal power supply allowing operation directly from 100 to 277 Vac 1 4 2 COMMUNICATIONS INTERFACE In applications where the user wishes remote configuration capability or wants to commu nicate trace information and or alarm
58. control a heating circuit it is necessary 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 CON TROL SETPOINT temperature When the control temperature is above the setpoint dead band 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 opera tional life Note See Section 7 2 of this manual for an explanation of Deadband Control Note that the MAXIMUM POWER SWITCH CURRENT RATING and CIRCUIT BREAKER CURRENT RAT ING settings are not available when the HTC is set to Deadband mode typically when switching a contactor 5 2 6 CYCLE TIME SETTING For proportional ambient contactor control mode only Purpose This parameter determines the minimum amount of time it will take for a com plete contactor ON OFF ON cycle Range 10 to 255 minutes Procedure Adjust the CYCLE TIME setting to yield the des
59. d 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 over ride signal will be received by the HTC via the external input select EXTERNAL INPUT as the OVERRIDE SOURCE Notes f the EXTERNAL INPUT is not configured as either INHIBIT or FORCE ON then OVER RIDE SOURCE will always automatically be set to REMOTE See Section 5 3 3 for further details If the autocycle feature is enabled it will continue to function even when an INHIBIT over ride 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 modes are inactive if a FORCE ON override signal is being received 33 34 Only the LOW TS ALARMS for temperature sensors used by the TS CONTROL MODE are inactive if an INHIBIT override signal is being received 5 2 22 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 com munications port and an upstream device It may be used to turn OFF the output of one or more controllers in order to reduce energy consumption to avoid peak demand surcharges remove power from unused circuits or remove power fro
60. d no alarms exist Setting N O Normally Open or N C Normally Closed Procedure Set the alarm output relays 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 steady illumination of the lamp when the circuit is operating correctly A light that is flashing or out indicates a fault condition A burned out lamp is readily identified if the HTC is set to flash the dry contact alarm output relay and the AC Alarm Relay output in case of alarm See the Section 5 3 4 5 3 6 LANGUAGE Purpose Defines which language the Operator Console is to use when 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 5 3 7 PASSCODE See Section 5 7 1 5 3 8 SCROLL DELAY SETTING Purpose Allows the user to modify the speed at which information is scrolled on the Operator Console for ease of viewing Range 0 07 to 0 25 seconds Procedure Decreasing the scroll delay value will cause the information on the display to scroll by faster Increasing the scroll delay value will cause the information on the display to scroll by slower 5 4 Temperature Sensor Alarms Configuration 36 This section defines the temperature related alarming functions of the 910 controller 5 4 1 TEMP
61. e Enable or disable alarming on reset as desired Note Normally the HTC RESET ALARM is left disabled since powering the controller off and on for maintenance or trouble shooting would require the user to reset this alarm every time If the particular 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 COMMUNICATIONS FAIL ALARM and an HTC RESET ALARM are logged provide an indication of how long the circuit has been OFF 5 5 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 tripping 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 Note that the CIRCUIT BREAKER LIMITING ALARM does not have to be enabled in order to adjust the CIRCUIT BREAKER CURRENT RATING setting Notes e This is a non latching alarm This alarm may be considered an advisory alarm If the measured current e
62. e If enabled the HIGH TS 1 ALARM allows for alarming of high temperature condi tions 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 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 tem perature setpoint unless the TS 1 high limit cutout feature is enabled Note This alarm should only be used for applications where a product that is sensitive to over temperature is involved General usage may result in nuisance alarms due to the flow of hot product or steam out This may be a case where the alarm should be enabled and non latching temperature alarming should be used A high temperature condition resulting from a forced on failure of the heating circuit should first be alarmed by the SWITCH FAIL URE ALARM See Section 5 5 18 for more information 5 4 4 TEMPERATURE SENSOR 2 FAILURE ALARM Purpose Enabling TS 2 FAILURE will provide indication of an open or shorted failure of TS 2 Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming of a failed temperature sensor connected to the TS 2 input as required Notes f no second sensor is installed this alarm should be disabled 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 us
63. e Time n a 10 min Switch Rating 30 0 Circuit Breaker n a 30 0 A Max Power n a 7200 W TS Fail Mode Off TS CTL Mode TS1 Fail Off TS 1 Type 1000 Plat TS 1 Lead Resist 0 Q TS 1 Hi Limit Disable TS 2 Type 1000 Plat TS 2 Lead Resist n a 0Q TS 2 Hi Limit Disable Autocycle Enable Autocycle Interval 8 Autocycle Units Hours Override Source Remote Load Shedding Disable Miscellaneous Setup Sub Menu Parameter Factory User Temperature Units SE Version V3 1x xx n a Ext Input Not used Flash Alarm Output Yes Alarm Output N C Language English Passcode 0 Scroll Delay 0 15 sec Load Defaults Communications Setup Sub Menu See user manual Parameter Protocol HTCBUS Addr Modbus Addr Modbus Sub Addr Baud Rate Parity Hardware Driver Profile Tx Delay Factory User HTCBUS factory ID n a 1 n a 0 Auto n a None None modem RS 232 RS 485 n a Auto Auto 0 06 sec n a Parameter may only appear if certain features are enabled Values shown in brackets are the Factory defaults if the settings are enabled This information defines the default 910 Series Control Module configuration as set by the Factory for firmware V3 1X 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 79 Tyco Thermal Controls WORLDWIDE HEADQUARTERS
64. e of both alarm and trip levels suitable for the particular installation Overcurrent Protection A unique overcurrent protection algorithm greatly reduces the possibility of damage to the circuit 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 910 will limit the energy let through to help prevent nui sance 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 it has measured 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 Operating at voltages less than design can cause serious loss of heater output The alarm ing of preset voltage deviations ensures availability of sufficient wattage output Power Limiting The 910 will control the maximum output wattage if the full load power exceeds the speci fied Maximum Power Setpoint This feature eliminates the need for low voltage transform ers in many applications and can assist in standardization of heating cable t
65. ems associated with it For example in the Monitor mode you may view temperatures load current resistance ground fault current voltage or power information This collection of data items is referred to as a menu Only one menu item may be viewed at a time The V lt keys move to the next previous item in the menu When you reach the end of the menu indicated by END 7 wraps you to the first item in the menu conversely lt gt wraps you to the last item in the menu Some of the items within a menu are actually entry points to sub menus these entries are indicated with at the end of the message To enter a sub menu press the gt key To move around in the menu use the 57 and A keys move to the next and previous items respectively The key exits the current menu and returns to the previous menu After approximately five minutes of keypad inactivity the current menu and mode will be exited and the console will revert to the Scan mode Note Some menus are dynamic that is some items appear or disappear depending on the configuration For example if you disable the Low Voltage Alarm then the corresponding Low Voltage Setpoint is not available and will not be displayed 3 4 3 CHANGING THE CONFIGURATION To change the Controller configuration follow the directions listed below Position the desired parameter menu item in the display Press the IX key to initiate an edit session If the console is l
66. ended past the 10 seconds until the alarm filter time has expired 5 2 19 AUTOCYCLE TIME INTERVAL Purpose AUTOCYCLE INTERVAL is the number of hours minutes between successive heat ing circuit 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 less than the AUTOCYCLE INTERVAL otherwise autocycling could affect the duty cycle If an AC ALARM becomes active during an autocycle but the AUTOCYCLE INTERVAL expires prior to the corresponding ALARM FILTER time then autocycling will continue until the ALARM FILTER time has elapsed For the earliest possible alarming of heating circuit problems the AUTOCYCLE INTERVAL should be set to a small value 5 2 20 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 5 2 21 OVERRIDE SOURCE 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 an
67. ent features Basic and Advanced The Basic Configuration Mode will limit the display to seven of the most commonly modi fied parameters while the Advanced Configuration Mode presents all of the available para meters Both Configure mode menus contain a parameter called FEATURE MODE which allows the user to specify which Configure mode is to be used Note All parameters that are enabled are active with their corresponding settings even if the Basic Configuration Mode is currently active Selecting the Basic Configure mode of opera tion simply hides the display of certain parameters but does not disable them 4 3 1 Basic Configure Mode Menu Table 4 4 Basic Configure Mode Menu CONTROL SETPOINT LOTS 1 LO LOAD SWITCH CONTROL MODE CIRCUIT BREAKER TEMP UNITS FEATURE MODE LOCK DATABASE UNLOCK DATABASE END 60 to 570 C 60 to 570 C 0 3 to 100 0 A Proportional Prop Amb SSR Deadband or Prop Amb Contactor 0 3 TO 100 0 A only if SSR is being used C or F Basic or Advanced Only if passcode is not 0 and database is unlocked Only if passcode is not 0 and database is locked 4 3 2 ADVANCED CONFIGURE MODE MAIN MENU Menu items with a trailing indicate an entry point to a sub menu To enter a sub menu use V and A to position the menu item in the display and then press gt Note that the con troller remembers where you are in the Configure
68. er 5 4 5 LOW TEMPERATURE SENSOR 2 ALARM Purpose If enabled the LOW TS 2 ALARM allows for alarming of low temperature condi tions 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 tempera ture setpoint Notes f 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 37 38 minimum 5 C differential between low temperature alarming and the CONTROL SET POINT temperature will minimize nuisance alarming due to momentary dips in tempera ture 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 temperature if fail safe mode uses the temperature from TS 2 5 4 6 HIGH TEMPERATURE SENSOR 2 ALARM Purpose If enabled the HIGH TS 2 ALARM allows for alarming of high temperature condi tions 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 HIG
69. f non neutral based power sources be opened upon detection of a Ground Fault Multi pole switch configurations should be used on non neutral based power systems Check the requirements with your local Electrical Authority 5 5 8 LOW VOLTAGE ALARM Purpose Alarms voltage levels that are lower than a preset limit for the application Alarm Mask ENABLE or DISABLE Range 10 to 330 Volts Procedure Adjust the LOW VOLTAGE ALARM level to the desired value Note that the LOW VOLTAGE ALARM must be enabled in order to adjust the LOW VOLTAGE ALARM level Note It is recommended that the LOW VOLTAGE ALARM always be enabled 5 5 9 LOW VOLTAGE ALARM FILTER TIME SETTING Purpose The LOW VOLTAGE ALARM FILTER will prevent LOW VOLTAGE ALARMS from being indicated until a low voltage condition has existed for the duration of the LOW VOLT AGE ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW VOLTAGE ALARM FILTER time to the desired value Note that 41 42 the LOW VOLTAGE ALARM must be enabled in order to adjust the LOW VOLTAGE ALARM FILTER time Notes e f 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 then the alarm will not be indicated again until the entire alarm f
70. g indicated until a high resistance condition has existed for the duration of the HIGH RESISTANCE ALARM FILTER time Range 0 to 12 seconds 43 44 Procedure Adjust the HIGH RESISTANCE ALARM FILTER time to the desired value Note that the HIGH RESISTANCE ALARM must be enabled in order to adjust the HIGH RESIS TANCE ALARM FILTER time Notes e f 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 Ifthe user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 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 instal lations where the power source may experience periodic fluctuations surges and or brown out conditions alarming on resistance deviation offers an improved method of monitoring tracer integrity than simple LOW and HIGH CURRENT ALARMS Since the ratio of voltage to current is monitored the HIGH and LOW RESISTANCE ALARMS offer cable monitoring that is relatively immune to voltage fluctuations Range 2 00 to 2000 00 Q Procedure The NOMINAL RESISTANCE value can only be set if either the LOW
71. h default values Procedure Select the LOAD DEFAULTS function in the Miscellaneous Setup sub menu using the Operator Console keypad Note This function will also overwrite the communication configuration parameters which could affect existing communications to the controller 5 7 7 FEATURE MODE Purpose Provides two types of menus on the Operator Console for configuring the 910 Setting BASIC or ADVANCED Procedure Select BASIC if access to only the seven most common parameters is required Select ADVANCED if access to all of the 910 parameters is required Section 6 Monitored Parameter Details 6 1 Introduction 6 2 Analog Readings The following text provides a brief summary of each of the measured and calculated para meters that the 910 Series Control Module provides to the user Detailed information regarding settings alarms limits etc may be found in Section 5 of this manual Detailed information regarding the display of these variables using the Operator Console may be found in Section 4 2 of this manual For detailed information regarding the display of these variables using the Model 780 GCC 9000 refer to the GCC user manual 6 2 1 CONTROL TEMPERATURE Purpose This is the temperature that the controller uses to determine whether its output switch should be on or off Depending on the TS CONTROL MODE setting and whether one or two RTDs are installed the CONTROL TEMPERATURE may be derived from TS 1 or
72. he tracer uses 2 The alarm LED will flash approximately once per second when the controller has detect ed an alarm condition The two additional LEDs are used to indicate external communications activity and are only used when an optional communications interface is installed The Rx LED flashes to show that the Controller is receiving information via its communications port The Tx LED flashes when the Controller is transmitting information via its communications port 3 4 1 OPERATING MODES The console operates in one of four modes and is related to the basic function the operator selects Mode Function Scan This is the default mode In this mode the console sequentially displays load current temperature and setpoint readings Alarm Invoked when you press the SHIFT key followed by the ALARM key This mode allows you to examine or reset any alarms that may exist The LED above the ALARM key is illuminated while in this mode Monitor Invoked when you press the SHIFT key followed by MONITOR key In this mode you may examine any of the controller readings such as temperature load current etc The LED above the MONITOR key is illuminated while in this mode Configure Invoked when you press the SHIFT key followed by CONFIG key In this mode you may examine or alter the controller configuration The LED above the CONFIG key is illuminated while in this mode 3 4 2 MENUS Each of the operating modes has a list of data it
73. his 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 situation 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 910 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 then 59 8 3 Common Alarms What to Look for 60 an actual ground fault condition may exist in the cable 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 The 910 has a wide range of alarming features that may be selectively enabled or disabled to allow the monitoring and indication of trouble conditions Described below are the differ ent alarm conditions available on the 910 their meanings and possible causes 8 3 1 High TS 1 TS 2 Temperature This alarm appears when the temperature exceeds the HIGH TS ALARM temperature set ting Cause of Alarm Alarm temperature setting too close to maintain temperature Flow of
74. iate operating manual for instructions on accessing controller parameters using these devices Note The Operator Console and 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 if the corresponding HIGH LIMIT CUTOUT has been enabled ENA to incorrect design or factors outside those considered by the design m This section describes the setup parameters that relate to the 910 5 2 1 CONTROL SETPOINT TEMPERATURE Purpose The CONTROL SETPOINT temperature is the value at which the heat trace con troller maintains the circuit temperature through either proportional proportional ambient SSR proportional ambient contactor or deadband control depending on the controllers configuration The CONTROL SETPOINT temperature is compared to the temperature measured by the control temperature 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 temperature The HTC will switch the output ON and OFF in an attempt to maintain this temperature Notes See Section 7 2 of this manual for an explanation of Proportional Proportional Ambient SSR Proportional Ambient Contactor and Deadband Control algorithms When usi
75. iding the temperature control without having to modify the CONTROL SETPOINT temperature or any other configuration parameter Procedure Press the TEST key on the Operator Console or select the TEST TRACING func tion to force the output switch on for approximately 30 seconds After the test time has expired the unit will automatically revert back to normal operation Notes This feature only overrides temperature control it does not override other control para meters such as power limiting If load shedding is active then TEST TRACING is inhibited 5 7 5 DISPLAY TEST Purpose The DISPLAY TEST feature provides an easy method of illuminating each display segment and all the LEDs of the Operator Console to ensure that they are functioning prop erly Procedure Select DISPLAY TEST and watch the Operator Console to verify that each dis play segment and each LED is illuminated during the test sequence Note Pressing any key on the Operator Console keypad during the DISPLAY TEST will cause the DISPLAY TEST to abort 5 7 6 LOAD DEFAULTS Purpose To provide a quick method of setting all of the controller s configuration parame ters to the factory default configuration parameters as defined in Appendix G In additional all of the maintenance data parameters are reset Note that all load shedding parameters including fail safe are configured with default values The CONSOLE SETPOINT MAXIMUM and MINIMUM are also configured wit
76. ilter time has expired 5 5 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 tracing circuit Alarm Mask ENABLE or DISABLE Range 10 to 330 Volts Procedure Adjust the HIGH VOLTAGE ALARM level to the desired value Note that the HIGH VOLTAGE ALARM must be enabled in order to adjust the HIGH VOLTAGE ALARM level 5 5 11 HIGH VOLTAGE ALARM FILTER TIME SETTING Purpose The HIGH VOLTAGE ALARM FILTER will prevent HIGH VOLTAGE ALARMS from being indicated until a high voltage condition has existed for the duration of the HIGH VOLT AGE ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the HIGH VOLTAGE ALARM FILTER time to the desired value Note that the HIGH VOLTAGE ALARM must be enabled in order to adjust the HIGH VOLTAGE ALARM FILTER time Notes e f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 12 LOW RESISTANCE ALARM Purpose Alarms heater resistance levels that have decreased from the NOMINAL RESIS TANCE setting by more than the selected amount Alarm Ma
77. inks The blinking digit identifies the digit that you are editing Use A or 57 to set the desired value Use 4 or move to a different digit To enter a negative value scroll to the first leftmost digit until a appears in the display Pressing P while on the last rightmost digit saves the new value Pressing lt while on the first leftmost digit ends the edit session without altering the parameter 3 4 6 PASSCODE PROTECTION The 910 Series Controller provides a passcode for protection of its configuration You may view any portion of the configuration with the console locked however when you attempt to initiate an edit session by pressing gt you are prompted to enter the passcode Entering the passcode is just like entering any other numeric value see Section 3 4 5 Changing a Numeric Parameter Once the console is unlocked you may edit any configuration parameter The console will automatically re lock after approximately five minutes of keypad inactivity or until the user explicitly locks it Notes Setting the programmed passcode to 0 disables passcode protection The console does not have to be unlocked to reset alarms 3 4 7 FEATURE MODES There are two types Configuration Menus in the 910 Series Controller 1 A Basic Configuration Menu which only contains seven parameters 2 An Advanced Configuration Menu which contains all of the parameters Both types of Configuratio
78. ired contactor ON OFF time for a particular 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 calcu lated every time the contactor is required to change state Notes 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 396 This results in a minimum contactor ON time of 18 seconds 29 30 5 2 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 acceptable level Range 0 3 to 100 0 Amps Procedure Adjust the SWITCH CURRENT RATING setting to the match the current rating of the output device i e 30 0 Amps 5 2 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
79. is disrupted in any way This will return temperature 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 shed ding operation before the controller may be set up for load shedding control There are three parameters that must be set up in the controller to completely 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 applica tion 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 and its alarm temperature must be less than the CONTROL SETPOINT temperature otherwise 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 Section 8 Troubleshooting 8 1 Operator Checks 8 2 Common Problem Areas These parameters may 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 manual for details on how to set up these options Note that the Operator Console may be used to enable or disable the load shedding feature but not set any of the other load shedding parameters Notes Fail safe mode is a
80. just the setting to the desired temperature units F or C Note To minimize possible confusion it is recommended that the temperature units be set the same on the HTC and any other communicating devices 5 3 2 VERSION OF FIRMWARE AND HARDWARE Purpose The first three digits indicate the revision level of the firmware programmed into the controller As new features are added to the HTC the firmware revision level is incre mented to allow the user to determine which features are available for the particular unit being used 5 3 3 EXTERNAL INPUT PORT Purpose This input port may be used as an OVERRIDE SOURCE to sense a remote dry contact closure This will override the controller s temperature control and force its output switch off or on Setting NOT USED INHIBIT or FORCE ON Procedure If the EXTERNAL INPUT is not being used select NOT USED If a remote dry contact closure should force the output switch off then select INHIBIT If a remote dry con tact closure should force the output switch on then select FORCE ON If the EXTERNAL INPUT is set to INHIBIT or FORCE ON then OVERRIDE SOURCE must be set to EXT INPUT Notes e When used with the INHIBIT FORCE ON feature a contact closure sensed by the EXTER NAL INPUT will initiate the INHIBIT FORCE ON mode An open input will cause the con troller to revert to normal temperature control operation One possible use of the INHIBIT feature is to use an external device such a
81. ller output will be fully on for 1 30 of the CYCLE TIME setting before the duty cycle is calculated again If the temperature sensed by the control sensor is equal or greater than the CONTROL SETPOINT temperature then the output will have a duty cycle of 0 The controller out 55 7 3 Load Shedding Control Mode 56 put will be off for 1 30 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 contactor control since ambient temperature is being monitored rather than pipe tempera ture Also note that if an AC alarm with an alarm filter time greater than 0 is detected the contactor will not toggle until the alarm filter time has expired Load shedding is a control mode that may be programmed and initiated only by an external communicating 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 9000 When using a GCC load shedding is initiated by a contact closure or Opening on one of the four contact inputs on the GCC Each contact input initiates a load shedding command for the group of controllers associated with that contact inpu
82. lue as the TS 1 LEAD RESISTANCE 5 2 14 TS 1 HIGH LIMIT CUTOUT Purpose When enabled the TS 1 high limit cutout feature will override the CONTROL SET POINT 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 Enable or disable the cutout feature as desired Notes 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 temperature setting 31 32 e faTS 1 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 f the TS 1 HIGH LIMIT CUTOUT feature is enabled then the HIGH TS 1 ALARM tempera ture setting can be set regardless of whether the HIGH TS 1 ALARM is enabled 5 2 15 TS 2 TYPE 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 Nickel Iron NI FE Procedure Select the type of RTD that is connected to the TS 2 input Note If a 2 wire 100 O Nickel Iron NI FE RTD is selected then the TS 2 LEAD RESIS TANCE must be entered see Sec
83. lways disabled if the SWITCH CONTROL MODE is set to either of the two proportional ambient control modes or the TS CONTROL MODE EXT INPUT FAIL OFF ON If the TS CONTROL MODE uses both TS 1 and TS 2 to calculate the control temperature the HTC will turn on its output if the following conditions are met oad shedding is active fail safe mode is enabled the control temperature falls below either of the LOW TS ALARM settings both TS 1 and TS 2 have their LOW TS ALARMS enabled AFORCE ON override signal has higher priority than a load shedding signal An INHIBIT signal has higher priority than fail safe mode 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 a Return Authorization form and number prior to returning any units for repair Upon receipt of the controller or to check the controller for an indication of normal opera tion 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 In order to determine if a fault is associated with the heat tracing wiring or the controller it will be necessary to troubleshoot the wiring and tracer circuit If the fault remains remove power from the controller and exch
84. m circuits which may be subjected to steam cleaning Setting ENABLE or DISABLE Procedure Enable or disable the load shedding control mode as desired Note To completely configure the HTC for load shedding operation the following additional parameters must be set up 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 Controller See the appropriate Section of the GCC manual for further details Notes Fail safe mode is not supported when using proportional ambient SSR or proportional ambient contactor modes For fail safe mode to function at least one LOW TS ALARM of the controlling temperature sensor s must be enabled and the corresponding LOW TS ALARM temperature setting must be less than the CONTROL SETPOINT temperature 5 2 23 CONSOLE SETPOINT MAXIMUM Purpose When using the Operator Console the maximum setting of the CONTROL SET POINT 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 temper ature setting to a dangerous level Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the CONSOLE SETPOINT MAXIMUM temperature value to limit the maxi mum allowable CONTROL SETPOINT TEMPERATURE that may be set using the Operator Console The CONSOLE SETPOINT MAXIMUM may only be set using a communicating
85. mode if you temporarily switch to a dif ferent mode such as the Monitor mode Switching back to the Configure mode will return you to the same menu item Note A few of the controller pa rameters that are often used have been duplicated in the Advanced Configure mode main menu for quick access These parameters Lo TS 1 Lo Load Hi GFI GFI Trip may also be accessed using their respective sub menus Table 4 5 Advanced Configure Mode Main Menu CONTROL SETPOINT 60 to 570 C LOTS1 60 to 570 C LOLOAD 0 3 to 100 0 A HI GFI 20 to 250 mA GFI TRIP 20 to 250 mA FEATURE MODE Basic or Advanced TS ALARMS CONFIG Note that the menu items with a trailing indicate the OTHER ALARMS CONFIG entry point to a sub menu POINT SETUP MISC SETUP COMMUNICATIONS SETUP LOCK DATABASE Only if passcode is not 0 and database is unlocked UNLOCK DATABASE Only if passcode is not 0 and database is locked END This sub menu is used to set up alarms that relate to any of the temperature sensors Each alarm may be ENAbled or DISabled and if the alarm is ENAbled an alarm setting may be entered 4 3 3 TS ALARMS CONFIG SUB MENU This sub menu is used to set up alarms that relate to any of the temperature sensors Each alarm may be ENAbled or DISabled and if the alarm is ENAbled an alarm setting may be entered 21 22 CONTROL SETPOINT 20 C LOTS 1056 LOLOAD 1 0A HI GFI
86. n Menus contain a Feature Mode parameter which allows the user to select which type of Configuration Menu is most desirable 3 4 8 QUICK NOTES ON OPERATION Remember the following basic rules for efficient Console use Use the SHIFT key followed by the appropriate function key ALARM MONITOR or CONFIG to select the operating mode e Use A and 57 to move around in the menu Use gt to enter a new menu enter a new value or select a menu item Use lt to exit the current menu or cancel an edit Section 4 Operator Console Modes 4 1 Alarm Mode 18 The Alarm mode is invoked when you press the SHIFT key followed by the ALARM key This mode allows you to examine and reset any alarms that may exist Use A V to examine the next previous active alarm 4 1 1 RESETTING ONE ALARM To reset an alarm press P You are prompted for confirmation answering YES resets the alarm and advances you to the next alarm 4 1 2 RESETTING ALL ALARMS To reset all active alarms press P You are prompted for confirmation press lt gt to select ALL and press gt to accept 4 1 3 MONITOR MODE TRACKING The Monitor mode tracks the Alarm mode If the Monitor mode is selected while viewing an alarm the controller will enter the MONITOR menu and display an appropriate reading For example if you are examining a High Load Current Alarm and then select the Monitor mode the starting point within the MONITOR menu will be the load current
87. n against harmful interference when the equipment is operated in a commer cial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications 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 Section 1 Overview 1 1 Introduction 1 2 Controllers Covered by this Manual 1 3 Product Overview This manual provides information pertaining to the installation operation testing adjust ment and maintenance of the Tyco Thermal Controls DigiTrace Model 910 Series Heat Tracing Controller Additional copies of this user manual may be ordered separately through your Tyco Thermal Controls representative or online at www tycothermal com using the document number H56873 This document covers the 910 Series Heat Trace Controllers and its available options The information coi
88. n the controller Some of these modes require further explanation in order to fully understand and implement their operation This section describes the control modes available in the HTC and how to set their associat ed parameters 7 2 Switch Control Modes There are four different SWITCH CONTROL modes associated with the HTC The following is an explanation of their implementation in the controller and the differences between them 7 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 con trol 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 then 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 PROPORTIONAL BAND setting then 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 temperatu
89. nals Terminal No Alarm relay dry contact output 14 Alarm relay dry contact output 15 Ground 4 12Vdc nom Out 3 AC Alarm and Control Signals Terminal No L1 Line out 1 L2 Neutral out 2 AC alarm relay 12 AC alarm relay 13 2 7 3 EXTERNAL CONTACT INPUT OUTPUT These input terminals are used to implement the inhibit and override features Refer to Section V of this manual for programming details and Appendix C for example wiring dia grams Miscellaneous Signals Terminal No External input 4 6 External input 7 2 7 4 COMMUNICATION SIGNAL CONNECTIONS The communications terminal assignments change based on the type of option installed If present in a 910 Control Module the type of communications interface will be identified by a label located on the front of the control module Figure 2 1 Communications wiring should use twisted pair shielded cable Shields on communications 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 inter faces RS 485 2 Wire Connections Communication Signal Terminal No Receive transmit data 16 Receive transmit data 17 Shield 18 5 232 3 Wire Connections Communication Signal Terminal No Receive data 16 Transmit data 17 Common 18 Modem Interface Connections Communication Signal Terminal No Modem 16 Modem 17 Shield 18 2 7 5 POWER CONNECTIONS All of the p
90. ncides with the specific releases of firmware for the 910 product which are listed on the front page As Tyco 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 910 against the version number listed on the front of this manual This may be displayed using the Operator Console or a communi cating device As subsequent changes are made supplements to this document will be issued and included in manuals shipped after the firmware is released Supplements will make specific reference to the operational or functional changes and are available at www tycothermal com 1 3 1 DESCRIPTION The 910 Series electronic Heat Tracing Controller controls monitors and communicates alarms and data for one heating circuit The ability to install the units in Class 1 Division 2 areas supports direct field installation if desired It is available with a solid state relay SSR output for use in hazardous areas or with electro mechanical relay EMR output for use in ordinary non hazardous areas 1 3 2 FEATURES A detailed description of available features may be found in Section V of this manual Highlights of specific features follow Keypad and Alphanumeric Display A six character alphanumeric LED display provides the operator with la
91. ng the Operator Console the CONTROL SETPOINT temperature range may be limited by the CONSOLE SETPOINT MAXIMUM and MINIMUM values see Sections 5 2 23 and 5 2 24 This is a safety feature to prevent users in the field from modifying the CONTROL SETPOINT temperature setting to a dangerous level 27 28 5 2 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 Procedure Using the Operator Console enter the desired text 5 2 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 7 2 for a complete explanation of these controlling techniques as implemented in the HTC Setting PROPORTIONAL PROPORTIONAL AMBIENT SSR PROPORTIONAL AMBIENT CONTACTOR or DEADBAND Procedure Select the desired control technique Note that deadband control and propor tional 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
92. o 9 seconds equal to the last digit of the HTCBUS communications address see Section 5 6 2 Once the start up delay has timed out the controller will begin normal operation The 910 may be programmed using the Operator Console or if a communications option is installed with an external communicating device For instructions on the operation of these devices refer to the corresponding operating manuals For complete instructions on pro gramming the 910 see the Programming and Configuration Section of this manual Section 3 Operator Console and Operation 3 1 Alphanumeric Display The console incorporates a six character fourteen segment plus decimal LED display Messages and prompts that are greater than six characters long are scrolled allowing more meaningful non cryptic messages to be used 3 2 Keypad The local keypad consists of six keys that allow you to select the console mode function that you are interested in For certain keys the SHIFT key selects an alternate function as shown by the text above that key Key SHIFT TEST shift ALARM lt BACK shift MONITOR gt ENTER shift CONFIG Function Press to activate a SHIFTed function the next key pressed uses the alternate shifted function The SHIFT LED illuminates indicating the next key uses the alternate shifted function Pressing SHIFT again cancels the alternate shifted function Turns on tracing for 30 seconds When prefixed by the SH
93. ocked you are prompted to enter the passcode The present setting will flash on the display to indicate that you are editing the parameter Use the A and v keys to change the value The operation of the gt and varies depends on the type of data being editing See the fol lowing sections for details Note Once you have initiated an edit session you must end it before switching to another mode or invoking another function An edit session ends when you enter a new value using the gt key or you back out of it using the key 3 4 4 CHANGING A NON NUMERIC PARAMETER To change a non numeric parameter e g an alarm mask setting follow the directions below Position the appropriate parameter in the display Press the 4 key to initiate the edit session If the console is locked you are prompted to enter the passcode The present setting will flash on the display to indicate that you are editing the parameter Use A or v until the desired value appears in the display Pressing gt saves the new value Pressing 4 ends the edit session without altering the parameter 3 4 5 CHANGING A NUMERIC PARAMETER To change a numeric parameter e g the control setpoint follow the directions below Position the appropriate parameter in the display Press the gt key to initiate the edit session If the console is locked you are prompted to enter the passcode The present value is displayed and the last rightmost digit bl
94. omentarily approximately 10 seconds applies power to the heating circuit at the selected interval It is used to test the integrity of the heating cir cuit Alarms present at the time of autocycle then become latched and remain active after the completion of the autocycle function Autocycling effectively eliminates the need for pre ventive maintenance by automatically verifying the heating circuit integrity Setting ENABLE or DISABLE Procedure Enable or disable the autocycling feature as desired If the feature is disabled you will not be prompted to enter the AUTOCYCLE INTERVAL or AUTOCYCLE UNITS Notes e Autocycling 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 lim iting SSR option only Autocycling is inhibited if the controller is in the load shedding mode See Section 7 3 If autocycling is enabled the HTC will always autocycle for 10 seconds when power is initially applied If autocycling is enabled and TS FAIL MODE OFF and all the control temperature sen sors have failed the HTC will still perform an autocycle If an alarm condition with an alarm filter time greater than 0 appears during the auto cycling then the autocycle will be ext
95. one of the temperatures will reset all of them 6 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 consumed on a particular trace circuit for the purposes of energy management or gathering of data for future design criteria The value of this accumulator is written to the controller s non volatile 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 Operator Console 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 214 748 364 7 kW hours 6 3 3 CONTACTOR CYCLE COUNTER Purpose This feature indicates the total number of off to on transitions a contactor has made since the last time the CONTACTOR CYCLE COUNTER was reset This serves as a method to perform preventative maintenance on the contactor according to the manufactur specifications This count 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 CONTACTOR CYCLE COUNTER may be reset to zero using the Operator Console or a communicating device Note Once the CONTACTOR CYCLE COUNTER reaches 999 999 999 it will stop counting
96. onsole Purpose This feature indicates the highest instantaneous load current measured since the last time the PEAK LOAD CURRENT was reset This value is written to the controller s non volatile 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 6 3 7 PEAK GROUND FAULT CURRENT Note The PEAK GROUND FAULT CURRENT is not displayed on the 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 non volatile memory once every 24 hours or whenever any main tenance data is reset by the user Procedure The PEAK LOAD CURRENT may only be reset to zero using a communicating device 6 3 8 EXTERNAL INPUT STATUS Note The EXTERNAL INPUT STATUS is not displayed on the optional Operator Console Purpose This feature indicates the actual status of the external input regardless of the con troller s configuration This may be useful if the user 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 communicating device 53 Section 7 Control Modes 7 1 Introduction There are several different types of control modes i
97. ontroller or accessories except lamps in optional alarm pilot lights The unit is designed to be modular and easily changed out in the field in a matter of minutes A 910 appearing inoperative should be returned to the nearest Tyco Thermal Controls Service Center for service Warning Tampering with the 910 components without approval from Tyco Thermal Controls could result in the product s warranty being void 63 Appendix A Specifications 64 Specifications are 25 C unless otherwise noted and are subject to change without notice System Ratings Storage Ambient Approvals Classification Wiring Terminal Ratings Signal Terminals Power Terminals Ground Lugs Assembly Ratings Operating Temperature Enclosures Solid State Relay Rating Electromechanical Relay Rating Control Module Ratings Operating Temperature Power Requirements Output Power Control Modes Temperature Inputs Temperature Measurement Range Voltage Measurement Range Current Measurement Range GF Current Measurement Range Dry Contact Alarm Relay Output AC Alarm Relay Output 40 F to 185 F 40 C to 85 C CSA C US CI I Div 2 Grps A B C D and Ex nA IIA IIB IIC Zone 2 e SSR Version T code T4 Ordinary locations SSR and EMR versions 28 12 AWG strip length 0 2 30A 22 8 AWG strip length 0 47 torque 10 7 in lb 1 2 N m 14 6 AWG torque 12 in Ib 1 35 N m 40 F to 140 F 40 C to 60 C FRP
98. or RS 485 or 1200 BAUD MODEM or 300 BAUD MODEM TxDELAY 0 00 to 2 50 S END Section 5 Configuration Parameter Details 5 1 Introduction 5 2 Point Setup Parameters The sections that follow explain the various functions of the 910 controller and how they may 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 per tain to the particular function Setting and using the alarming functions of the 910 controller is a two step procedure The alarm must be enabled or disabled as desired When using the Operator Console access to all alarming functions is available using the ADVANCED CONFIGURE mode sub menus When using either the Model 780 GCC 9000 Group Communications Controller the alarm masks may be found in the HTC SET UP Section Please see the appropriate operating manual for instructions on accessing controller parameters using these devices The corresponding alarm point value may be modified appropriately for the application When using the Operator Console access to the alarm points is also available using the ADVANCED 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 appropr
99. osure compromises the NEMA 4 rating 2 6 1 Controller Installation and Removal Caution Always 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 HTCBus communications address ADDRESS 123456 DigiTrace Communications status indicators E E let nl on Alarm status indicator Output status indicator L1 Line in L2 Neutral in L1 Line out to tracer L2 Neutral out to tracer RTD communications inhibit override input alarm dry contact output D910 010 L AC alarm output Fig 2 1 Control module face Wiring diagrams for typical configurations are included in Appendix C of this manual Caution Always verify wiring connections before applying power to the controller or con nected 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 910 uses lever operated spring loaded terminals for signal wiring See Appendix A for allowable wire sizes and recommended insu lation strip lengths 12 2 7 1 T
100. ower terminals are labeled 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 manu facturer s specification See Appendix A for allowable wire sizes recommended insulation 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 retightened 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 maintained Be certain to use the proper size screwdriver for the termi nal 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 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 8 Initial Power up 2 9 Setup for the 910 14 2 7 6 INPUT POWER The 910 controller may be powered directly from a
101. pay shipping charges to 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 910 Controller will execute its programming instructions properly Tyco Thermal Controls does not warrant that the operation of the hardware or software or firmware will be uninterrupted or error free The foregoing warranty shall not apply to defects resulting from improper or inadequate maintenance by the Buyer Buyer supplied software or interfacing unauthorized modifica tion or misuse operation outside of the specifications for the product or improper installa tion No other warranty is expressed or implied Tyco Thermal Controls disclaims the implied warranties 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 dam ages 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 reason able protectio
102. rations should include expected atmospheric conditions accessibility for maintenance and testing the location of existing conduits and hazardous area rating Ambient 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 2 7 Wiring Communications interface type label optional Mounting hole dimensions for the standard enclosures are shown in Appendix B Conduit entries should be made in the bottom of the enclosure if possible to reduce the possibility of water entry or leakage Conduit entries must be drilled punched following the enclosure manufacturers recommendations Use bushings suitable for the enclosure type and install such that the completed installation remains waterproof For nonmetallic enclosures 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 problem 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 encl
103. re falls within the 0 100 band Proportional Contro Temperature Band Control Sensor Temperature Duty Cycle Setpoint proportional band 0 Setpoint proportional band 2 50 Setpoint 100 7 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 since this would cycle the contactor too quickly In these situations 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 may set the DEADBAND value The controller monitors the temperature of the trace circuit and compares it to the CON TROL SETPOINT temperature as in the proportional control mode If the control sensor temperature is above the CONTROL SETPOINT temperature by more than the DEADBAND 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 very simple control algorithm but it works very effectively in heat trace applications where the temperature of a traced system changes relatively slowly 54 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
104. reading Once the Monitor mode has been selected you may move around in the menu using 57 and A 4 1 4 ALARM MESSAGES Table 4 1 lists sample alarms and the corresponding starting point in the Monitor mode menu if it is invoked from the Alarm mode Table 4 1 Alarm Messages Sample Alarm Message LOTS 1 2 C HITS 1 102 C TS 1 FAIL ALARM LOTS 2 4 0 5 2 105 C TS 2 FAIL ALARM CTL TS FAIL ALARM LO LOAD 0 5A HI LOAD 21 0A HI GFI 52 mA GFI TRIP 77mA LO VOLT 85V HI VOLT 140 V LO RESIST 3 38 Q RESIST 9240 OVERCURRENT TRIP ALARM SWITCH FAIL ALARM HTC RESET ALARM SWITCH LIMITING ALARM C B LIMITING ALARM POWER LIMITING ALARM EEROM DATA FAIL ALARM CONTACTOR COUNT 200000 4 2 Monitor Mode Monitor Mode Starting Point TS 1 temperature TS 1 temperature TS 1 temperature TS 2 temperature TS 2 temperature TS 2 temperature Control temperature Load current Load current Ground fault current Ground fault current Voltage Voltage Resistance Resistance Load current Load current Time since last reset Load current Load current Power n a Contactor cycle count The Monitor mode is invoked when you press the SHIFT key followed by the MONITOR key This mode allows you to test the heat tracing and examine any of the analog readings The data is updated in real time providing the user with a method of viewing tracer information as it occurs 4 2 1 MAIN MENU Table 4
105. rge easy to read mes sages and prompts eliminating complex and cryptic programming Six individual keys are provided to quickly access alarming and operational information 40 F to 140 F 40 C to 60 C Operation Extended temperature operation permits installation in all but the harshest environments Single or Dual Temperature Sensor Inputs The ability to utilize one or two temperature sensor TS inputs allows the selection of one of eight control modes and programming of all temperature parameters High and Low Temperature Alarms High and low temperature alarms are offered for both temperature sensor inputs of each control point High and Low Current Alarms The 910 offers full adjustment of both the high and low alarm points over the entire current measurement range Solid State or Electromechanical Relay EMR Output The 910 is available with either a solid state relay SSR or an electromechanical relay EMR output switch With the SSR option the user may select a time proportional control algorithm a simple deadband control mode or one of two ambient control algorithms The EMR version always uses either the deadband 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 may be displayed in milliamps The availability of the actual ground fault level gives the user the choic
106. rk to avoid messaging conflicts Either MODBUS protocol must be selected in order to set the MOD BUS ADDRESS 5 6 4 MODBUS SUB ADDRESS Purpose The MODBUS SUB ADDRESS along with the MODBUS ADDRESS define the com munications address to be used by the controller when using either MODBUS protocol to communicate with a MODBUS compatible device 47 48 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 messaging conflicts Either MODBUS protocol must be selected in order to set the MODBUS SUB ADDRESS Note Since a 910 HTC does not use all 65 535 data registers that are available for each MODBUS ADDRESS the data register range is subdivided to allow up to 32 HTCs to share the same MODBUS ADDRESS This increases the number of HTCs allowed on a single Modbus port from 247 to 7 904 247 x 32 This requires that any HTC sharing the same MODBUS ADDRESS as another HTC must have its own unique MODBUS SUB ADDRESS 5 6 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 will support the various data rates it is recom mended that the setting be set to
107. rm Alarm setting too close to normal operating voltage Incorrect wiring Power surge 8 3 10 LOW VOLTAGE This alarms voltage levels which are less than the LOW VOLTAGE ALARM setting Cause of Alarm Alarm setting too close to normal operating voltage Damaged power cable Incorrect VOLTAGE TURNS RATIO Brown out conditions Loss of power to the circuit 8 3 11 OVERCURRENT TRIP If the controller is unable to start the cable due to high current or after attempting to soft start it the controller will trip its output switch off Cause of Alarm Excessive in rush current Incorrect wiring e Damaged cable 61 62 8 3 12 SWITCH FAILURE This alarm indicates that the controller senses current flow when the output switch should be off Cause of Alarm Some other device energized heat trace Output switch has failed closed 8 3 13 HTC RESET This alarm is latched when power is restored after an interruption Used to identify intermit tent power losses Cause of Alarm Circuit breaker tripped Power line transient 8 3 14 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 Cause of Alarm Power applied to trace circuit is being limited to the MAXIMUM POWER setting 8 3 15 C B LIMITING This alarm indicates that the solid state relay is limiting the average current th
108. rocedure Adjust the LATCH TS ALARMS setting to the desired mode latching or non latching Notes e f 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 non latching 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 then the HTC should be configured for latch ing temperature alarms This setting does not affect the TS FAILURE ALARMS these are always latching 5 4 10 CONTROL TEMPERATURE SENSOR FAILURE ALARM Purpose Control TS FAILURE ALARM indicates a failure of the temperature sensor desig nated as the control sensor One of eight T5 CONTROL MODES may be selected These modes determine which TS input s is are designated to provide the control temperature See Section 5 2 11 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 sensor 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 This section defines the non temperature related alarming functions of the 910 controller current ground fault voltage and resistance 5 5 1 LOW LOAD CURRENT ALARM P
109. rol 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 SSR control since ambient temperature is being monitored rather than pipe temperature 7 2 4 PROPORTIONAL AMBIENT CONTACTOR CONTROL FOR USE WITH CONTACTORS When an HTC using a contactor is used to control the output based on the ambient temper ature 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 temperature 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 tempera ture PROPORTIONAL BAND setting and the CONTROL SETPOINT temperature setting The controller monitors the ambient temperature and compares it to the CONTROL SET POINT temperature as in proportional ambient SSR control If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPOR TIONAL BAND setting then power is applied to the trace with a duty cycle of 100 The contro
110. s If the HTC controller indicates a failure of an RTD Ensure that the RTD is a 3 wire 100 Platinum Type for V3 00 For V3 11 and up ensure that the TS TYPE setting matches the RTD being used TURN THE POWER TO THE CONTROLLER OFF BEFORE PROCEEDING Disconnect the RTD wiring from the input terminals Measure the RTD s resistance between the source WHT and sense WHT leads at the controller 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 insuf ficient wire gauge and correct as necessary Measure the RTD s resistance between the source WHT or sense WHT lead and the common RED lead of the RTD at the controller should be between 60 and 330 Q depending on the temperature and the lead resistance See Appendix E or Appendix F Verify that the RTD is wired correctly the heat tracing controllers will always be termi nated in the order source WHT sense WHT common RED When wiring to the 910 the terminals are marked as follows Terminal No Description 19 Shield 20 TS 1 Source WHT 21 TS 1 Sense WHT 22 TS 1 Common RED 8 Shield 9 TS 2 Source WHT 10 TS 2 Sense WHT 11 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 terminated at one end only norm
111. s a flow meter to provide a contact closure if there is flow in a line As long as the line has ade quate flow the heating will be off INHIBITed from operating See Appendix C for typical connection diagrams when using this input EXTERNAL INPUT must be set to INHIBIT or FORCE ON before OVERRIDE SOURCE can be set to EXT INPUT Setting EXTERNAL INPUT to NOT USED or TEMPBUS will auto matically set OVERRIDE SOURCE to REMOTE 5 3 4 FLASH ALARM OUTPUT SETTING Purpose Programs both the alarm output relays dry contact and AC alarm for flashing or steady output in case of an alarm condition Setting YES Flash or NO Steady Procedure Set the alarm output relays to flash or not to flash on an alarm condition whichever suits the application Notes If the alarm output is used to drive a pilot light it is recommended that YES be selected 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 35 and be extinguished due to a bulb failure or loss of power f multiple alarm outputs from different controllers are wired in series i e multi point panels set this parameter to NO steady 5 3 5 ALARM OUTPUT NORMAL STATE Purpose Configures both the alarm output relays dry contact and AC alarm for normally open or normally closed operation The normal condition is assumed to be when the HTC is powered an
112. s during cold startup These currents may exceed the overcurrent trip limit and the controller will not be able to soft start the trace circuit If this condition persists please contact your nearest sales office for recommendations and solutions to this problem 5 5 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 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 off therefore no protection features are available ground fault trip power limiting etc If a SWITCH FAIL URE ALARM is detected the unit should be serviced immediately 5 5 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 A transient 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 Procedur
113. s to another device such as a Group Communications Controller 780 Series GCC 9000 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 Two standard assemblies are available and stocked at the Factory 1 An SSR version for use in ordinary or Class Division 2 areas 2 An EMR version for use in ordinary locations only 1 6 Ordering and Configuration Guide DIGITRACE 910 CONTROLLERS FACTORY INVENTORY Description DigiTrace 910 controller in an 8 x 10 FRP enclosure with window Catalog Number Part Number 910 E1FWL EMR2 10170 001 2 pole 30 A EMR Controls a single circuit with a 2 pole electromechanical relay Approved for ordinary areas only DigiTrace 910 controller in an 8 x 10 FRP enclosure with window 910 E1FWL EMR2 485 10170 015 2 pole 30 A EMR Controls a single circuit with a 2 pole electromechanical relay Includes an isolated 2 wire RS 485 communication option Approved for ordinary areas only DigiTrace 910 controller in an 8 x 10 FRP enclosure with window 910 E1FWL SSR2 10170 002 2 pole 30 A 277 V SSR Controls a single circuit with a 2 pole solid state relay Approved for Class I Div 2 areas DigiTrace 910 controller in an 8 x 10 FRP enclosure with window 910 E1FWL SSR2 485 10170 016 2 pole 30
114. sk ENABLE or DISABLE Range 1 to 100 deviation from NOMINAL RESISTANCE Procedure Adjust the LOW RESISTANCE ALARM deviation to the desired value Note that the LOW RESISTANCE ALARM must be enabled in order to adjust the LOW RESISTANCE deviation Notes This feature would not normally be enabled It can be used effectively to guard against accidental paralleling of heating circuits Care must be taken when using this alarm fea ture with heating cables that exhibit a variable resistance with temperature Low resis tance alarming may not be practical when the load has an 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 transformer No LOW RESISTANCE ALARMS will be generated if the measured voltage is below the LOW VOLTAGE ALARM setpoint regardless if 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 LOW RESISTANCE ALARMS will only be generated if the output switch is on 5 5 13 LOW RESISTANCE ALARM FILTER TIME SETTING Purpose The LOW RESISTANCE ALARM FILTER will prevent LOW RESISTANCE ALARMS from being indicated until a low resis
115. sted for the duration of the HIGH GFI ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the HIGH 6LI 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 f 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 If the user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 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 G F 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 In order to implement a ground fault trip function ALL NON GROUNDED power conductors must be opened upon detection of a ground fault condition Note National Electrical Codes may require that all legs o
116. switch off and will not retry or pulse its output switch again At this point the OVERCURRENT TRIP ALARM is latched on Notes The controller is NOT a safety cutout or an overcurrent protective device as defined by the National and Canadian Electrical Codes NEC and CEC A protective device such as a cir cuit breaker or fuse must be included as part of a proper design and be selected in accor dance with the requirements defined in the National Electrical Code NEC and or the Canadian Electrical 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 trou bleshooting 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 It is highly recommended that this alarm be left enabled since an overcurrent trip con dition would normally represent a serious problem Note that this is a factory set alarm value and disabling the alarm does not disable the overcurrent trip function In some appli cations the use of self regulating cable will produce very high in rush current
117. t 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 is 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 command If no command is present the controller resumes normal opera tion If a load shedding command is present the controller will continue to hold its output OFF until one of three conditions occurs The GCC contact input or zone definition bits of an external communicating device that initiated load shedding clears and the command to terminate load shedding mode is issued Communications are interrupted between the controller and its communicating device as in the case of a damaged communications wire Approximately 30 seconds after com munications ceases the controller will return to normal operation Communications between the controllers and the external communicating device go off line for approximately two minutes as occurs when the 760 Hand Held Programmer is used to communicate with the controller oo Note The controller will return to normal operation if communications between the GCC or external communicating device and the controller
118. t for applications that do not require power limiting 5 2 10 TS FAIL MODE Purpose This parameter determines whether the HTC turns the output switch ON or OFF if all selected temperature sensors fail to provide a valid control temperature Setting OFF or ON Procedure If the HTC should turn the output switch off when it cannot read a valid control temperature then select OFF otherwise if the output switch should turn on then select ON Note This parameter is part of the T5 CONTROL MODE 5 2 11 TEMPERATURE SENSOR CONTROL MODE Purpose The TS CONTROL MODE allows the selection of one of eight possible temperature control 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 eight 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 CONTROL 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 Where OFF ON Controllers output switch turned OFF or ON as determined by the TS FAIL MODE Example With a TS CONTROL MODE of CONTROL ON AVERAGE FAIL TO GOOD the con troller will measure both sensors TS 1 and TS 2 averaging the two temperature values display the results and cycle the heater ON or OFF to maintain the CO
119. tance 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 Note that the LOW RESISTANCE ALARM must be enabled in order to adjust the LOW RESIS TANCE ALARM FILTER time Notes e f 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 Ifthe user resets an alarm while the alarm condition is still exists then the alarm will not be indicated again until the entire alarm filter time has expired 5 5 14 HIGH RESISTANCE ALARM Purpose Alarms heater resistance levels that have increased from the NOMINAL RESIS TANCE setting 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 indicate the failure of one or more heating zones It may also be used to monitor a failed series type cable or connection in three phase applications while minimiz ing nuisance alarms created by voltage fluctuations Alarm Mask ENABLE or DISABLE Range 1 to 250 deviation from NOMINAL RESISTANCE Procedure Adjust the HIGH RESISTANCE ALARM level to the desired value Note that the HIGH RESISTANCE ALARM must be enabled in order to adjust
120. the HIGH RESISTANCE deviation Notes Using the LOW CURRENT ALARM feature to ensure that unexpected decreases in current consumption 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 three phase installations the LOW CURRENT ALARM setting must be chosen as close to the lowest expected current as possible to detect failed zones or cable degradation or a lost phase The problem with such a close 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 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 HIGH RESISTANCE ALARMS will only be generated if the output switch is on 5 5 15 HIGH RESISTANCE ALARM FILTER TIME SETTING Purpose The HIGH RESISTANCE ALARM FILTER will prevent HIGH RESISTANCE ALARMS from bein
121. the HTC configura tion menu otherwise a PROPORTIONAL BAND setting will be available No MAXIMUM POWER SWITCH CURRENT 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 5 2 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 proportion al or proportional ambient SSR modes are normally used allowing for more precise tem perature control 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 Procedure Adjust the PROPORTIONAL BAND setting to the desired differential from the CONTROL SETPOINT temperature Notes See Section 7 2 of this manual 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 tem perature control application significant energy savings may be realized by setting the PROPORTIONAL BAND to match the expected range of operating ambient temperatures Tracer design
122. tion 5 2 16 5 2 16 TS 2 LEAD RESISTANCE 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 5 2 17 TS 2 HIGH LIMIT CUTOUT Purpose When enabled the TS 2 high limit cutout feature will override the CONTROL SET POINT 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 Notes 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 temperature setting If a TS 2 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 If the TS 2 HIGH LIMIT CUTOUT feature is enabled then the HIGH TS 2 ALARM tempera ture setting can be set regardless of whether the HIGH TS 2 ALARM is enabled 5 2 18 AUTOCYCLE ENABLING Purpose The autocycle function m
123. trols repre sentative for information regarding other available sizes and configurations B 1 Standard Fiberglass EMR Assembly 10170 001 8 50 6 25 0 41 T 6 00 gt 0 3 dia 0 3 dia O 9 16 lhe 6 25 10 00 8 25 10 50 11 00 i E 0 OF 0 3 dia 0 3 d LEFT SIDE VIEW FRONT VIEW 2 pole 30A EMR Assembly in a Fiberglass fr S Enclosure with Window Model 910 E1FWL EMR2 BACKPLANE 65 B 2 Optional Stainless Steel EMR Assembly 10170 003 7 87 0 10 T 5 91 5 31 bos dia 0 25 dia 4 I 4 53 _ 0 0 25 dia LEFT SIDE VIEW 0 25 dia FRONT VIEW 2 pole 30A EMR Assembly in a Fiberglass Enclosure with Window Model 910 E1FWL EMR2 66 BACKPLANE B 3 Standard Fiberglass SSR Assembly 10170 0002 9 65 9 E 8 50 j 6 25 0 41 L 6 00 O 03 da 0 3 dia SH 1 6 25 gt 10 00 B 25 10 c 1 4 TNS OP 1 o Q 4 0 3 dia 0 3 dia LEFT SIDE VIEW FRONT VIEW 2 pole 30A EMR
124. uding the Model 780 GCC 9000 Group Communications Controller If you are communicating directly with the controller using a different device select the MODBUS protocol For a detailed description of the controllers MODBUS mapping please refer to 910 Series Heat Trace Controller Modbus Protocol Interface document 5 6 2 HTCBUS ADDRESS Purpose Defines the communications address to be used by the controller when using the HTCBUS protocol to communicate with a Model 780 GCC 9000 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 the Factory and identified by the label on the top of the controller module see Fig 2 1 It is recommended that the pre assigned address be used whenever possible to minimize the chances of an address being duplicated in the user s system 5 6 3 MODBUS ADDRESS Purpose The MODBUS ADDRESS along with the MODBUS SUB ADDRESS define the com munications address to be used by the controller when using either MODBUS protocol to communicate with a MODBUS compatible device 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 netwo
125. urpose Alarms current levels which 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 5 5 14 Alarm Mask ENABLE or DISABLE Range 0 3 to 100 0 Amps Procedure Adjust the LOW CURRENT ALARM level to the desired value Note that the LOW CURRENT ALARM must be enabled in order to adjust the LOW CURRENT ALARM level Notes 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 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 ALOW CURRENT ALARM may also result from a switch failed open The controller can 39 40 not 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 t may be advantageous to consider using the HIGH RESISTANCE ALARM to indicate a cable fault when using certain types of heaters See Sections 5 5 12 and 5 5 14 for an explanation of the resistance alarming feature 5 5 2 LOW LOAD CURRENT ALARM FILTER TIME SETTING Purpose The LOW CURR
126. xceeds the 45 46 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 5 5 21 POWER LIMITING STATUS SSR ONLY Purpose 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 tracing 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 Note that the POWER LIMITING ALARM does not have to be enabled in order to adjust the MAXIMUM POWER setting Notes This is a non latching alarm This alarm may be considered more appropriately an advisory alarm and is normally dis abled It will be active if the MAXIMUM POWER setting 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 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
127. ypes SSR options only Autocycling The controller will momentarily 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 eliminates 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 Random Start A startup delay between 0 and 9 seconds ensures that all units do not come on line at the same time 1 4 Modular Components 1 5 Controller Assemblies 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 communi cations are available for applications requiring direct interfacing to other devices The modem version maintains compatibility with legacy products including the Group Communications Controller Model 780 GCC 9000 With heat trace data at the user s fin gertips historical trending of temperatures power consumption or other parameters are available for analysis and system optimization CSA C US The 910 Series of controllers are approved for Class Division 2 Groups A B C D hazardous locations making them ideal for direct installation in the field This may save the significant expense of wiring ba

DigiTrace® 910 Series Heat Trace Controller

Contents

Download Pdf Manuals

Related Search

Related Contents

DigiTrace&reg; 910 Series Heat Trace Controller

Contents

Download Pdf Manuals

Related Search

Related Contents

DigiTrace® 910 Series Heat Trace Controller