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DigiTrace 910 Series Heat Trace Controller

1. 37 5 6 CommiuniCatlons Setup ORENSE Er doc E De noes 44 5 7 Operator Console 5 2 sese pact pede enean duo dee Ada 46 Section Mornitored Parameter 56 22555512 eset ee eden Ee reas 48 n E 48 6 REAGING gia M 48 6 3 Maintemance nie 49 Section 7 Mo deS ss 51 51 7 2 Switch Control Modes ooi ptit nce ete 51 773 L0ad shedding Control Mode 2 TE O reacts 53 Section 8 Tro bleshootihg icr rtt 54 8 amp ER m 54 8 2 ProblermiAreas eet fes tres ede 54 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 2477 8 3 Common Alarms What to Look for 56 Section 9 Maintenance lt ccseccesvencecisscacesessecssncacevcocecderdesedsnsncececaceveesesvonduuavsncedvstsecavssvadsebedeedeatessersbessedscocnexces 60 2 1 Operator Malnteriaree aee a eaten 60 9 2 Replaceable Parts Appendix A SpecifICatlOris rii yes err Dr Y en en DO PEE FOYER Y YER
2. 0 65 5 91 787 5 31 LL 034 0 3 dia O i k y 453 9 84 7 84 9 84 11 00 Y Y gp 0 3 dia 0 3 dia LEFT SIDE VIEW FRONT VIEW DigiTrace 2 pole 30A EMR Assembly in a Fiberglass Enclosure with Window Model 910 E1FWL EMR2 BACKPLANE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 65 77 5 910 SERIES HTC CONTROL MODULE DIMENSIONS 4 75 4 85 1 6 20 6 60 Y Mounting slots suitable for a 8 machine screw THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 66 77 APPENDIX C WIRING DIAGRAMS The following drawings provide sample wiring diagrams for the 910 Series control products and optional accessories Please contact your local Pentair Thermal Management representative for information regarding other available options C 1 TS WIRING SHIELD 192 DRAIN SOURCE 204 WHT RTD 1 SENSE 214 WHT 100 SHIELD 8 DRAIN SOURCE 9 WHT RTD 2 SENSE 105 WHT 100 n COMMON 110 RED Pt RTD Note Temperature s
3. 6 3 7 PEAK GROUND FAULT CURRENT IMPORTANT The PEAK GROUND FAULT CURRENT is not displayed 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 maintenance data is reset by the user Procedure The PEAK LOAD CURRENT may only be reset to zero using a communicating device 2 6 3 8 EXTERNAL INPUT STATUS IMPORTANT The EXTERNAL INPUT STATUS is not displayed 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 50 77 SECTION 7 CONTROL MODES 7 1 INTRODUCTION 7 2 SWITCH CONTROL MODES There are several different types of control modes in 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 associated parameters There are four di
4. BACKPLANE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 62 77 2 OPTIONAL STAINLESS STEEL EMR ASSEMBLY 10170 003 7 87 5 31 0 10 5 91 0 25 0 25 dia 4 55 0 25 dia 0 25 dia LEFT SIDE VIEW FRONT VIEW 2 pole 30A EMR Assembly E a Fiberglass Enclosure with Window zm Model 910 E1FWL EMR2 29280 Qo 29 BACKPLANE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 63 77 B 3 STANDARD FIBERGLASS SSR ASSEMBLY 10170 0002 8 50 0 65 6 25 j 0 41 r 6 00 qi wi 03 dia 0 3 dia O 6 25 10 00 8 25 10 50 11 00 1 2 L 1 o 0 3 dia 0 3 dia LEFT SIDE VIEW FRONT VIEW DigiTrace 2 pole 30A EMR Assembly in a Fiberglass Enclosure with Window Model 910 E1FWL EMR2 BACKPLANE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 64 77 4 OPTIONAL STAINLESS STEEL SSR ASSEMBLY 10170 004
5. 7 EXTERNA JRY CONTACT COMMON iz 4 CLOSE ACTIVATE INHIBIT OVERRIDE MODE S EKN MAX TOTAL P RESISTANCE INHIBIT ZOVERRIDE INPUT USING EXTERNAL DRY CONTAC D910 009 C 5 2 EXTERNAL INHIBIT OVERRIDE USING A DC SIGNAL 910 CONTROLLER e VDC 3 5VDC TO 24VDC NOMINAL 10 EXTERNAL INPUT COMMON INHIBIT OVERRIDE INPUT USING EXTERNAL DC SIGNAL D910 009 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 70777 APPENDIX D HTC LOAD SHEDDING SEQUENCE Normal mode control Load shedding command received HTC load shed enabled All other contact inputs active 1 HTC holds its output OFF for 30 seconds Is communications active 2 Control at low temp alarm setpoint Fail safe HTC temp All matching HTCs set mode their outputs to OFF enabled 3 HTC display indicates 3 load shedding mode 4 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 71 77 APPENDIX 100 PLATINUM RTD TABLE DIN 43760 100 N PLATINUM RESISTANCE TEMPERATURE RTD 0 00385 OHMS OHM C Ohms c Ohms c Ohms c 60 25 100 148 159 18 155 311 250 48
6. 1 TS Failure 5 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 e Measure the resistance between the source and sense WHT leads at the controller it should not exceed 40 0 Excessive lead resistance will cause a TS FAILURE ALARM and must be corrected Look for loose terminals excessive lead length or insufficient wire gauge and correct as necessary Measure the RTD s resistance between the source WHT or sense WHT lead and the common RED lead of the RTD at the controller should be between 60 and 330 0 depending on the temperature and the lead resistance See Appendix E or Appendix Verify that the RTD is wired correctly the heat tracing controllers will always be terminated in the order source WHT sense WHT common RED When wiring to the 910 the terminals are marked as follows THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 54 77 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 th
7. 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 complete contactor ON OFF ON cycle Range 10 to 255 minutes Procedure Adjust the CYCLE TIME setting to yield the desired contactor ON OFF time fora 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 calculated Va every time the contactor is required to change state IMPORTANT e f the calculated duty cycle is 0 or 100 then the contactor will not change state and the duty cycle will not be calculated again for a time period CYCLE TIME 30 The minimum cycle time setting is 10 minutes and the minimum controller output duty cycle is 3 This results in a minimum contactor ON time of 18 seconds 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 devi
8. 910 CONTROLLER 12VDC 34 4 DRY DRY CONTACT ALARM RELAY T is UTPUT pm COMMON 45 DRY CONTACT THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 68 77 4 2 USED AS SWITCHED DC CONTACT 910 CONTROLLER gt _34 42 DRY CONTACT _L ALARM RELAY 385 dayne SWITCHED ON ALARM POWERED ALARM CONTACT C 4 3 USED AS AN AC ALARM RELAY 910 CONTROLLER LI LINE OUT gt 14 e AC ALARM 0 754 277VAC RELAY 3 AC ALARM OUTPUT L2 NEUTRAL OUT ALARM RELAY C 4 4 Used as a Powered AC Alarm Relay 910 CONTROLLER LI LINE OUT gt 1 ied 1 0 755 277VAC TO jw RELAY B m L1 LINE SWITCHED Le NEUTRAL OUT L2 NEUTRAL ALARM POWERED AC ALARM RELAY THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 69 77 5 EXTERNAL INPUT OUTPUT PORT WIRING C 5 1 EXTERNAL INHIBIT OVERRIDE USING A DRY CONTACT 910 CONTROLLER 1eVDC 3 16 EXTERNAL INPUT
9. PROFILE AUTO or 3 WIRE RS 232 or RS 485 or 1200 BAUD MODEM or 300 BAUD MODEM TxDELAY 0 00 to 2 50 5 END THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 25 77 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 pertain to the particular function Setting and using the alarming functions of the 910 controller is a two step Procedure 1 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 submenus 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 2 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 val
10. HITS2 60T0570 C LOTS FILTERS 0 to 999 only if LO TS 1 or 2 are enabled HITS FILTERS 0 to 999 MIN only if HI TS 1 or 2 are enabled LATCH TS ALARMS YES or NO 5 FAIL ENA 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 temperature 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 DlISabled If the alarm is ENAbled an alarm setting and filter setting may be entered THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 21 77 CONTROL SETPOINT LO LOAD HI GFI GFI TRIP TS ALARMS CONFIG 20 10 1 0A 50 mA 75 mA OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP o 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 ENA DIS 0 3 to 100 0 010 12 S ENA or D 0 3 to 100 0 0 12 5 HI GFI F GF GF LO LO LO VOLT F HI HI HI VOLT F LTER TRIP TRIP VOLT VOLT LTER VOLT VOLT LTER ENA or 20 25 0012 20 25 10 to 33 0012 ENA or 10 to 33 5 mA 5 mA 5 V S V
11. 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 Supervisor 10391 002 1 DIGITRACE 910 CONTROLLERS MADE TO ORDER Contact factory for lead time THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 7 77 DigiTrace 910 controller in 8 x 10 stainless steel 910 E1SW EMR2 10170 003 20 enclosure with window 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 910 E1SW EMR2 485 10170 017 20 enclosure with window 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 910 E1SW SSR2 10170 004 25 enclosure with window 2 pole 30 A 277 V SSR Controls a single circuit with a 2 pole solid state relay Approved for Class Div 2 areas DigiTrace 910 controller in an 8 x 10 stainless steel 910 E1SW SSR2 485 10170 018 25 enclosure with window 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 SENSORS 100 ohm platinum RTD wit
12. exe ea EE pev eu Fares Appendix B Typical Enclosure Dimensions 0 4 000000 sn nnn nnn n B 1 Standard Fiberglass EMR Assembly 10170 001 B 2 Optional Stainless Steel EMR Assembly 10170 003 x Standard Fiberglass SSR Assembly 10170 0002 Optional Stainless Steel SSR Assembly 10170 004 sese 65 B 5 910 Series HTC Control Module Dimensions Appendix C Wiring Diagrams E is 2 tere 5 External Input Output Port Wiring m Appendix D HTC Load Shedding Sequence sssccccsesserceeeeseesesaesseeeenesseeeeseccneeusesceeeesasseeaeeesseeeeesseeceeeaae Appendix E 100 0 Platinum RID Tables DIN 43760 100 0 Platinum Resistance Temperature RTD 0 00385 Ohms Ohmy P C 72 Appendix F 100 0 Nickel Iron RTD Table ss Appendix G Factory Default Configuration 3 1 nennen nennen nnne nnns 74 orem 74 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 34 77 DIGITRACE 910 SERIES HEAT TRACE CONTROLLER Installation and Maintenance Instructions for Firmware Versions up to and Including V3 1X Notice The information
13. may have existed in a pipe then the HTC should be configured for latching temperature alarms e This setting does not affect the TS FAILURE ALARMS these are always latching THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 36 77 5 4 10 CONTROL TEMPERATURE SENSOR FAILURE ALARM Purpose Control TS FAILURE ALARM indicates a failure of the temperature sensor designated as the control sensor One of eight TS 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 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 4 sensor as required IMPORTANT This alarm should always be enabled If the controller experiences a Control TS Failure it will turn the output off or on specified by TS FAIL MODE until this alarm is cleared 5 5 OTHER ALARMS CONFIGURATION 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 Purpose 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 DISA
14. 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 programmed 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 the tracer uses 2 The alarm LED will flash approximately once per second when the controller has detected 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 OPERATIONAL BASICS 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
15. 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 6 77 includes indicators for alarm and output status and an integral Operator Console An internal 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 provided 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 communicate trace information and or alarms to another device such as a Group Communications Controller 780 Series GCC 9000 an optional communic
16. 1 PASSCODE Purpose The four digit numeric PASSCODE feature stops unauthorized users from modifying the controller s configuration parameters using the Operator Console Range 0000 to 9999 Procedure Enter the desired PASSCODE the Miscellaneous Common Setup submenu using the Operator Console keypad A PASSCODE of 0000 disables the lockout feature 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 IMPORTANT The PASSCODE 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 programming has been completed THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 46 77 Procedure Select the LOCK DATABASE function the end of the Configuration Mode Menu to lock out Operator Console configuration modification access The display will confirm the operation by displaying a DATABASE LOCKED message amp IMPO
17. 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 29 110 230 234 91 365 689 319 99 620 1148 144 17 115 239 236 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 72 77 APPENDIX F 100 0 NICKEL IRON RTD TABLE Ohms c Ohms Ohms c 69 8 73 100 133 4 68 155 218 2 210 410 71 1 70 095 134 8 71 160 220 1 212 415 72 3 67 90 136 3 73 165 222 0 215 420 73 1 65 85 137 8 76 170 223 9 218 425 74 3 62 80 139 3 79 175 225 8 221 430 75 5 59 75 140 8 82 180 227 7 223 435 76 7 56 70 142 3 85 185 229 6 226 440 78 0 53 65 143 8 87 190 231 5 229 445 78 8 51 60 145 3 90 195 233 5 232 450 80 0 48 55 146 8 93 200 235 4 235 455 81 2 45 50 148 4 96 205 237 4 237 460 82 2 42 45 149 9 98 210 239 3 240 465 82 9 40 40 151 5 101
18. 215 241 3 243 470 84 2 37 35 153 0 104 220 243 3 246 475 85 7 34 30 154 6 107 225 245 3 248 480 86 9 31 25 156 2 110 230 247 2 251 485 88 1 28 20 157 7 112 235 249 3 254 490 88 9 26 15 159 3 115 240 251 2 257 495 90 1 23 10 160 9 118 245 253 3 260 500 91 4 20 5 162 5 121 250 255 2 262 505 92 2 17 0 164 2 123 255 257 3 265 510 93 4 15 5 165 8 126 260 259 3 268 515 94 6 12 10 167 4 129 265 261 4 271 520 95 8 9 15 169 0 132 270 263 4 273 525 97 1 6 20 170 7 135 275 265 5 276 530 98 3 3 25 172 3 137 280 267 6 279 535 99 5 1 30 174 0 140 285 269 6 282 540 100 8 1 35 175 7 143 290 271 7 285 545 102 0 4 40 177 4 146 295 273 8 287 550 103 3 7 45 179 1 148 300 275 9 290 555 104 6 10 50 180 8 515 305 278 0 293 560 105 9 12 55 182 5 154 310 280 1 296 565 107 2 15 60 184 2 157 315 282 3 298 570 108 5 18 65 185 9 160 320 284 4 301 575 109 8 21 70 187 6 162 325 286 5 304 580 111 1 23 75 189 165 330 288 6 307 585 112 5 26 80 191 1 168 335 290 8 310 590 113 8 29 85 192 9 171 340 293 1 312 595 115 2 32 90 194 5 173 345 295 2 315 600 116 5 35 95 196 4 176 350 297 5 318 605 117 9 37 100 198 2 179 355 299 8 321 610 119 2 40 105 199 9 182 360 301 4 323 615 120 6 43 110 201 7 185 365 303 7 326 620 122 0 46 115 203 5 187 370 306 0 329 625 123 4 48 120 205 3 190 375 308 3 332 630 124 8 51 125 207 2 193 380 310 6 335 635 126 2 54 130 109 0 196 385 312 2 337 640 127 6 57 135 210 8 198 390 314 5 340 645 129 0 60 140 212 7
19. 410 110 62 28 95 139 161 04 160 320 252 19 415 719 64 30 90 130 162 90 165 329 253 90 420 788 66 31 85 121 164 76 170 338 255 61 425 797 68 33 80 112 166 61 179 347 257 32 430 806 70 33 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 55 67 175 84 200 392 265 80 455 851 80 31 50 58 177 68 205 401 267 49 460 860 82 33 45 49 179 51 210 410 269 18 465 869 84 27 40 40 181 34 215 419 270 86 470 878 86 25 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 94 12 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 50 199 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
20. 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 Full Digital Communications An optional internal communications interface allows the communication of alarms and analog data to a monitoring system Industry standard RS 232 or RS 485 serial communications are available for applications requiring direct interfacing to other devices The modem version maintains compatibility with legacy products including the Group Communications Controller Model 780 GCC 9000 With heat trace data at the user s fingertips historical trending of temperatures power consumption or other parameters are available for analysis and system optimization CSA C US 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 back to a centrally located electrical distribution center 1 4 MODULAR COMPONENTS The 910 Series controller is made up of two components Each component s primary function is described below 1 4
21. Deadband control on the HTC is implemented as follows e 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 CONTROL 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 Deadband Control Temperature Band Control Sensor Temperature Output State Setpoint deadband Off Setpoint On When the control sensor temperature is within the deadband the output does not change its state Also when using deadband control a contactor is not allowed to toggle faster than every two seconds If an AC alarm with an alarm filter time greater than 0 is detected the contactor will not toggle until the alarm filter time has expired THERMAL MAN
22. Terminals 28 12 AWG strip length 0 2 Power Terminals 30A 22 8 AWG strip length 0 47 torque 10 7 in lb 1 2 Ground Lugs 14 6 AWG torque 12 in lb 1 35 Assembly Ratings Operating Temperature 40 F to 140 F 40 to 60 EnclosuresFRP Nema 4X IP65 SS Type 304 Nema 4X IP65 Solid State Relay Rating 2 pole switching 30 A continuous 0 40 C derate linearly to 15 max 4 60 C resistive load 100 277 Vac max 80 1 sec in rush 625 1 cycle in rush Electromechanical Relay Rating 2 pole switching 30 A continuous 0 40 C derate linearly to 20 A max 4 60 C 100 277 Vac nom max Control Module Ratings Operating Temperature 40 F to 140 F 40 to 60 C Power Requirements 100 to 277 Vac nom 1PH 50 60 Hz 0 2A max 0 75A Aux AC output terminals Output Power 12 nom 250ma max Control Modes e Proportional Deadband Proportional Ambient SSR Proportional Ambient Contactor modes Adjustable 2 F to 90 F 1 to 50 C Temperature Inputs 2 RTD inputs 3 wire 1000 Platinum DIN 43760 a 0 003850 0 C or 2 3 wire 1000 Ni Fe open shorted sensor detection protection lead resistance compensated 0 to 200 per lead Temperature Measurement Range Voltage Measurement Range 76 F to 1058 F 60 to 570 C accuracy 0 5 of span 1LSD 80 to 295Vac
23. accuracy 1 of span 2LSD repeatability 1 5 of span Current Measurement Range 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 2 596 of reading resolution GF Current Measurement Range Dry Contact Alarm Relay Output 20 to 250ma accuracy 2 596 of span 2LSD at nominal load repeatability 4 of span 48Vac dc 500ma 10VA switching max AC Alarm Relay Output 0 75A 100 277 Vac nom max THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 61 77 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 Pentair Thermal Management representative for information regarding other available sizes and configurations B 1 STANDARD FIBERGLASS EMR ASSEMBLY 10170 001 r 8 50 6 25 0 41 6 00 i 03 da 03 dia M a 1 0 16 le 3 r 6 25 10 00 8 25 10 50 11 00 4 0 3 dia 0 3 dia LEFT SIDE VIEW FRONT VIEW 2 pole 30A EMR Assembly in a Fiberglass Enclosure with Window EE Model 910 E1FWL EMR2
24. and ensures drainage if the enclosure is not perfectly level Note that drilling holes in the enclosure compromises the NEMA 4 rating 2 6 1 Controller Installation and Removal 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 Explosion Hazard Do not install or remove the control module while the unit is powered ADDRESS 123456 DigiTrace 0910 HTCBus communications address Communications status indicators Alarm status indicator Output status indicator Communications interface type label optional RTD communications inhibit override input alarm dry contact output D910 010 L1 Line in L2 Neutral in L1 Line out to tracer L2 Neutral out to tracer L AC alarm output Fig 2 1 Control module face 2 7 WIRING Wiring diagrams for typical configurations are included in Appendix C of this manual Always verify wiring connections before applying power to the controller or connected circuits To avoid injury or equipment damage do not install or remove wiring while controller power is on To minimize the chance of loose connections the 910 uses lever operated spring loaded terminals for signal wiring See Appendix A for allowable wire sizes and rec
25. approximately five minutes of keypad inactivity the current menu and mode will be exited and the console will revert to the Scan mode IMPORTANT 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 e Press the P key to initiate an edit session f 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 the and keys to change the value The operation of the varies depends on the type of data being editing See the following 27 sections for details IMPORTANT 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 t gt key or you back out of it using the 4 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 e Press the 4 key to initiate the edit session f the console is locked you
26. are prompted to enter the passcode e The present setting will flash on the display to indicate that you are editing the parameter e Use or A 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 t key to initiate the edit session f the console is locked you are prompted to enter the passcode The present value is displayed and the last rightmost digit blinks The blinking digit identifies the digit that you are editing Use v or to set the desired value e Use or P to move to a different digit e To enter a negative value scroll to the first leftmost digit until a appears the display Pressing P while on the last rightmost digit saves the new value e Pressing 4 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 you are prompted to enter the passcode Entering the passcode is just like entering any other numeric val
27. as sensed by the first temperature sensor 15 1 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 609 to 570 C Procedure Adjust the LOW TS 1 ALARM temperature setpoint to the desired value Note that the LOW TS 1 ALARM must be enabled in order to adjust the LOW TS 1 ALARM temperature setpoint THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 34 77 57 IMPORTANT e This alarm should normally be enabled and the setpoint should be appropriate for the heating application Maintaining a minimum 5 C differential between low temperature alarming and the CONTROL SETPOINT temperature will minimize nuisance alarming due to momentary dips in temperature Another alternative to this is to configure the controller for non latching 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 Purpose If enabled the HIGH TS 1 ALARM allows for alarming of high temperature conditions as sensed by the first temperature sensor TS 1 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 609 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 temperature setpoint F unless the TS 1 high limit cutout feature is enabled IMPORTANT This alarm
28. data 4 16 Receive transmit data 17 Shield 18 RS 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 of the power 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 gt incorrect operation of the controller IMPORTANT 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 terminal blocks to minimize the chance of damage to the terminals If the controllers are installed in either a metallic or non metallic enclosure follow the enclosure manufacturer s recommendations for proper grounding Do not rely on conduit connections to provide a suitable ground Gr
29. 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 items 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 15 referred to as a menu Only one menu item may be viewed at a time The lt keys move to the next previous item in the menu When you reach the end of the menu indicated by END v wraps you to the first item in the menu conversely A 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 move around in the menu use the Vv and A keys move to the next and previous items respectively The 4 key exits the current menu and returns to the previous menu THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 15 77 After
30. no second sensor is installed this alarm should be disabled This alarm should be enabled and the setpoint should be appropriate for the heating application Maintaining a minimum 5 C differential between low temperature alarming and the CONTROL SETPOINT temperature will minimize nuisance alarming due to momentary dips in temperature Another alternative to this is to configure the controller for non latching temperature alarms This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT 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 conditions as sensed by the second temperature sensor TS 2 Alarm Mask ENABLE or DISABLE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 35 77 Range 76 F to 1058 F 609 to 570 C Procedure Adjust the HIGH TS 2 ALARM temperature setpoint to the desired value Note that the HIGH TS 2 ALARM must be enabled in order to adjust the HIGH TS 2 ALARM temperature setpoint 74 unless the TS 2 high limit cutout feature is enabled V IMPORTANT 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
31. 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 applications the use of self regulating cable will produce very high in rush currents 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 IMPORTANT The SWITCH FAILURE ALARM SHOULD ALWAYS BE ENABLED 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 If a SWITCH FAILURE ALARM is detected the unit should be serviced immediately 5 5 19 HTC RESET ALARM Purpose The HTC RES
32. selected when using contactors or when precise control and F advanced current handling functions are not required IMPORTANT If deadband is selected DEADBAND setting will be available in the configuration 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 equipped with SSRs is used to control a heating circuit proportional 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 IMPORTANT e See Section 7 2 of this manual for an explanation of how the three proportional modes use the PROPORTIONAL BAND setting e When using Series type constant wattage or self regulating tr
33. 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 FAILURE 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 F as required IMPORTANT e 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 e This alarm is always latched and must be reset by the user 5 4 5 LOW TEMPERATURE SENSOR 2 ALARM Purpose If enabled the LOW TS 2 ALARM allows for alarming of low temperature conditions as sensed by the second temperature sensor TS 2 Alarm Mask ENABLE or DISABLE Range 76 F to 1058 F 60 C to 570 C Procedure Adjust LOW TS 2 ALARM temperature setpoint to the desired value Note that the LOW 15 2 ALARM must be enabled in order to adjust the LOW TS 2 ALARM temperature setpoint IMPORTANT f
34. 201 395 316 8 343 650 130 5 62 145 214 5 204 400 319 1 346 655 131 9 65 150 216 4 207 405 320 6 348 660 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 734 77 APPENDIX G FACTORY DEFAULT CONFIGURATION V3 1X 910 SERIES HTC THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 74 77 BASIC MODE MENU other parameters are set as shown the Advanced Mode 5 5 Configuration Mode Menu Parameter Factory User Control Setpoint 68 F 20 C Lo TS 1 14 F 10 Lo Load 1 0A Switch Control Mode Deadband Circuit Breaker 30 0A Temperature Units F Feature Mode Basic ADVANCED MODE MENUS Configuration Mode Main Menu Parameter Factory User Control Setpoint 68 F 20 C LoTS 1 14 F 10 Lo Load 1 0A Hi GFI 20 mA GFI Trip 30 mA Feature Mode Advanced TS Alarms Configuration Sub Menu Parameter Factory User TS 1 Fail Enable LoTS1 Enable Lo TS 1 14 F 10 Hi TS 1 Disable Hi TS 1 n a 212 F 100 TS 2 Fail Disable Lo 152 Disable Lo TS 2 n a 14 F 109 Hi TS 2 Disable Hi TS 2 n a 212 F 100 Lo TS Filter 0 min Hi TS Filter n a 0 min Latch TS Alarms Yes CTL TS Fail Enable Other Alarms Configuration Sub Menu Paramete
35. 3 04 13 41 77 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 switch off and will not retry or pulse its output switch again At this point the OVERCURRENT TRIP ALARM is latched on IMPORTANT e 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 circuit breaker or fuse must be included as part of a proper design and be selected in accordance with the requirements defined in the National Electrical Code NEC and or the Canadian Electrical Code The controller cannot protect the SSR from short circuits or excessive overcurrent conditions Always ensure that the power is off prior to performing any maintenance or troubleshooting 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 IMPORTANT It is highly recommended that this alarm be left enabled since an
36. 6 MONITORED PARAMETER DETAILS 6 1 INTRODUCTION The following text provides a brief summary of each of the measured and calculated parameters 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 ANALOG READINGS 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 TS 2 or a combination of the two temperatures See Section 5 2 11 of this manual for further details regarding the TS CONTROL MODE settings 6 2 2 TS 1 TEMPERATURE Purpose This temperature is the value that the controller is reading from the RTD connected to its TS 1 input Depending on the TS CONTROL MODE it may be used to determine the CONTROL TEMPERATURE see Section 6 2 1 above IMPORTANT If the TS 1 input is not being used by the controller the 5 1 TEMPERATURE is not displayed 6 2 3 5 2 TEMPERATURE Purpose This temperature is the value that the controller is readi
37. 9 PENTAIR DigiTrace Digilrace 910 Series Heat Trace Controller INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS Firmware versions up to V3 1x DigiTrace 4 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 1 77 5 Certification Limited Warranty Warranty Exclusion Disclalmer et eee dede iet 4 Exclusive Remedies emnene 4 Conducted Radiated Emissions FCC DOC Statement of Compliance Section T OVEFVICW T M 5 VANECO AUCE ON 556 AER In Yee AS EY ou res 5 1 2 Controllers Covered by this Manual 1 3 Product Overview TA Modular Components asiste S Controler 6565 ct ikea csetera ert taped du ER RR 7 1 6 Ordering and Configuration Guides civ o o oo eot pe irr cette Cu 7 Section 2 Installation and Wiring 2 2 Initial SPC COM 9 2 3 Operator Safety 9 2 4 Operati
38. AGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 51 77 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 ona cycle by cycle basis 50 or 60 Hz power line cycle e This algorithm monitors ambient temperature and compares it to the CONTROL SETPOINT temperature If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting then power is applied to the trace with a duty cycle of 100 the controller output is fully on e f 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 output will be off e The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0 100 band Proportional Ambient SSR Control Temperature Band Control Sensor Temperature Duty Cycle Setpoint 0 Setpoint proportional band 2 50 Setpoint proportional band 10095 IMPORT
39. ANT 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 temperature this control mode should be used Proportional ambient contactor control on the HTC is implemented as follows The output may not be switched on off rapidly when using a contactor so proportional temperature control is implemented by applying the required duty cycle over the selected CYCLE TIME e 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 e The duty cycle is calculated each time the output toggles based on the ambient temperature PROPORTIONAL BAND setting and the CONTROL SETPOINT temperature setting e The controller monitors the ambient temperature and compares it to the CONTROL SETPOINT temperature as in proportional ambient SSR control If the temperature of the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting then power is applied to the trace with a duty cycle of 100 The controller output will be fully on for 1 30 of the CYCLE TIME setting before the duty cycle is calculated again e f the temperature sensed by t
40. ATURE MODE TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP LOCK DATABASE UNLOCK DATABASE END 60 to 570 60 to 570 0 3 to 100 0 A 20 to 250 mA GFI TRIP 20 to 250 mA Basic or Advanced Note that the menu items with a trailing indicate the entry point to a sub menu Only if passcode is not 0 and database is unlocked Only if passcode is not 0 and database is locked This sub menu is used to set up alarms that relate to any of the temperature sensors Each alarm may ENAbled 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 DlISabled and if the alarm is ENAbled an alarm setting may be entered THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 20 77 CONTROL SETPOINT 20 C LOTS1 10 C LOLOAD 1 0A GFI 50 mA GFI TRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP Table 4 6 TS Alarms Configuration Sub Menu TS1FAIL ENA or DIS LOTS1 ENA or DIS LOTS1 60 TO 570 C HITS 1 ENA or DIS HITS1 60 TO 570 C TS2FAIL ENA or DIS LOTS2 ENA or DIS LOTS2 60 TO 570 C HITS2 ENA or DIS
41. BLE 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 e For series type heating cables adjusting the LOW CURRENT ALARM to 50 of full load current will properly alarm a problem and reduce nuisance alarms due to voltage dips Parallel heaters should be adjusted to a level as close as possible to full load current 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 cannot detect a switch failure due to no current A no current condition would be identified by a LOW CURRENT ALARM if enabled and the analog value reported with the alarm will be 0 0 A 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 CURRENT ALARM FILTER will prevent LOW LOAD CURRENT ALARMS from being indicated until a low current condition has existed for the duration of the LOW CURRENT ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW CURRENT ALARM FILTER time to th
42. CLE 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 and does not require heating Setting REMOTE or EXT INPUT Procedure If the override signal will be generated remotely and received by the HTC via the optional communications interface select REMOTE as the OVERRIDE SOURCE If the over ride signal will be received by the HTC via the external input select EXTERNAL INPUT as the OVERRIDE SOURCE THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 31 77 IMPORTANT If the EXTERNAL INPUT is not configured as either INHIBIT or FORCE ON then OVERRIDE SOURCE will always automatically be set to REMOTE See Section 5 3 3 for further details e f the autocycle feature is enabled it will continue to function even when INHIBIT override signal is being received as long as load shedding is not active e Fail safe mode is inactive if an INHIBIT override signal is be
43. ENT 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 4 time IMPORTANT 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 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 indicated until a high GFI condition has existed for the duration of the HIGH GFI ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the HIGH GFI ALARM FILTER time to the de
44. ENT RATING setting to the heating circuit breaker size 1 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 F CURRENT RATING setting IMPORTANT e This is a non latching alarm e This alarm may be considered an advisory alarm If the measured current exceeds the level that would cause the upstream circuit breaker to release the HTC will begin to switch the SSR ON and OFF rapidly to limit the average current to an acceptable level 5 5 21 POWER LIMITING STATUS 658 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 IMPORTANT e This is a non latching alarm e This alarm may be considered more appropriately an advisory alarm and is normally disabl
45. ESISTANCE 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 8 3 19 EEROM DATA FAILURE This alarm indicates that the controller has detected a failure in its nonvolatile memory this is where all of the controller s configuration and calibration settings are stored This indicates an internal problem and the HTC should be replaced and returned to 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 is causing the contactor to toggle more than usual THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 59 77 SECTION 9 MAINTENANCE 9 1 OPERATOR MAINTENANCE The 910 series controller is designed to be a maintenance free product Once installed properly the only maintenance required is retightening of the te
46. ET 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 Va Procedure Enable or disable alarming on reset as desired IMPORTANT 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 42 77 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 CURR
47. INPUT FAIL OFF ON e If the 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 load 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 A FORCE ON override signal has higher priority than a load shedding signal An INHIBIT signal has higher priority than fail safe mode THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 53 77 SECTION 8 TROUBLESHOOTING 8 1 OPERATOR CHECKS IMPORTANT If the controller does not operate properly and is being returned to Pentair Thermal Management for service information must be provided as to why the unit was removed from service Contact the Pentair Thermal Management 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 operation follow the operational procedures shown below These procedures are designed to familiarize the operator with the controller and to provide an understanding of its operation 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
48. Iron NI FE RTD is selected then the TS 1 LEAD RESISTANCE must be entered manually see Section 5 2 13 5 2 13 TS 1 LEAD RESISTANCE For NI FE RTDs only THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 29 77 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 0 Procedure Measure the resistance of one of the Nickel Iron RTD leads from the RTD to the HTC s TS 1 input and use this value as the TS 1 LEAD RESISTANCE 5 2 14 TS 1 HIGH LIMIT CUTOUT Purpose When enabled the TS 1 high limit cutout feature will override the CONTROL SETPOINT temperature and force the controller output off if the TS 1 reading exceeds the HIGH TS 1 ALARM temperature setting This is a non latching condition so once the TS 1 reading drops below the HIGH TS 1 ALARM temperature setting the controller will resume normal operation Setting ENABLE or DISABLE Procedure Enable or disable the cutout feature as desired IMPORTANT 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 e Ifa TS 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 If the TS 1 HIGH LIMIT CUTOUT feature is enabl
49. 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 0012 1 to 100 0012 ENA or DIS 1 250 01012 5 2 00 to 2000 00 0 only if LO or is enabled ENA or DIS ENA or DIS ENA or DIS ENA or DIS or DIS ENA or DIS or DIS 5 i Ome oO moo oo ih 0 to 999999 ENA or DIS on on on on on Co on Co y if SSR is being used y if SSR is being used y if SSR is being used y if SSR is being used y if Deadband or Prop Amb ntactor are being used y if Deadband or Prop Amb ntactor are being used THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 22 77 4 3 5 POINT SETUP SUB MENU The Point Setup sub menu is used to configure parameters that relate directly to the specific control point Included in this menu are control mode settings circuit breaker and switch ratings autocycle set up parameters etc CONTROL SETPOINT 20 C LOTS1 10 C LO LOAD 10 GFI 50 mA GFI TRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP sec END Table 4 8
50. LOTS1 10 C LOLOAD 1 0A HI GFI 50 mA GFI TRIP 75 mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP Z Table 4 9 Misc Setup Sub Menu TEMP UNITS C or F VERSION V3 16 3 EXT INPUT NOT USED INHIBIT or FORCE ON FLASH ALARM OUTPUT YES or NO ALARM OUTPUT N C or N O 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 24 77 4 3 7 COMMUNICATIONS SETUP SUB MENU The settings found in this sub menu must be configured whenever an optional communications board is installed in the Control Module CONTROL SETPOINT 20 C LOTS 1 10 C LOLOAD 1 0A HI GFI 50 GFITRIP 75mA TS ALARMS CONFIG OTHER ALARMS CONFIG POINT SETUP MISC SETUP COMMUNICATIONS SETUP oe Table 4 10 Communications Setup PROTOCOL HTCBUS or MODBUS ASCII or MODBUS RTU HTCBUS ADDR 1 to 16777215 only if PROTOCOL HTCBUS MODBUS ADDR 1 to 247 only if PROTOCOL4HTCBUS MODBUS SUBADDR 01031 only if PROTOCOL4HTCBUS BAUD RATE AUTO or 9600 or 4800 or 2400 or 1200 or 600 or 300 PARITY or ODD or EVEN only if PROTOCOL4HTCBUS HARDWARE NONE OR MODEM OR RS 232 or RS 485 DRIVER AUTO or RS 485 or RS 232 or MODEM
51. OOD 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 controller 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 CONTROL 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 maintained based on this measured value If the remaining good sensor fails the controller will turn the heater OFF or ON as determined by the TS FAIL MODE setting The appropriate TS 1 or TS 2 FAILURE ALARM will be also be generated Procedure Select the control mode that best suits the application IMPORTANT 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 0 Platinum or 2 3 wire 100 0 Nickel Iron F Procedure Select the type of RTD that is connected to the TS 1 input IMPORTANT If a 2 wire 100 0 Nickel
52. 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 5 77 Ground Fault Alarm and Trip Ground Fault current levels are monitored and may be displayed in milliamps The availability of the actual ground fault level gives the user the choice of both alarm and trip levels suitable for the particular installation Overcurrent Protection A unique overcurrent protection
53. Point Setup Sub Menu TAG 19 ALPHANUMERIC CHARACTERS SWITCH CONTROL MODE PROPORTIONAL PROP AMB SSR DEADBAND or PROP AMB CONTACTOR DEADBAND 1 to 50 only if SWITCH CONTROL MODE is DEADBAND PROP BAND 1 to 50 C only if SWITCH CONTROL MODE is not DEADBAND CYCLE TIME 10 to 255 MIN only if SWITCH CONTROL MODE is not PROP AMB SWITCH RATING 0 3 to 100 0 only if SSR is being used CIRCUIT BREAKER 0 3 to 100 00 A only if SSR is being used MAX POWER 3 W to 33 000 W only if SSR is being used 5 FAILMODE OFF or ON TSCTLMODE TS 1 FAIL OFF ON or 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 LOWEST FAIL TO GOOD TS T TYPE 100 W PLAT or NI FE TS1LEADRESIST 1 to 20 000 Q only if TS 1 TYPE NI FE TS1HILIMIT ENA or 015 TS2TYPE 100 W PLAT or NI FE TS 2 LEAD RESIST 0 TO 20 000 0 only if TS 2 TYPE NI FE TS2HILIMIT ENA or DIS AUTO CYCLE ENA or 015 AUTO CYCLE INTERVAL 1 to 240 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 or 015 END THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 23 77 4 3 6 MISC SETUP SUB MENU The Misc Setup sub menu is used to configure miscellaneous parameters CONTROL SETPOINT 20 C
54. RTANT 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 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 PASSCODE will appear If the correct PASSCODE is entered then the display will confirm the operation by displaying a DATABASE UNLOCKED message 5 7 4 TEST TRACING Purpose The TEST TRACING feature provides an easy method of temporarily overriding 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 function 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 IMPORTANT e This feature only overrides temperature control it does not override other control parameters such as power limiting f 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 dis
55. S 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 RS 232 or RS 485 or 1200 BAUD MODEM or 300 BAUD MODEM Procedure Select the PROFILE to be compatible with other devices that will be connected THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 45 77 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 communications interface installed in the 910 e AUTO Selects a communications profile based the data rate the type of communi cations interface installed in the 910 e 3 WIRE RS 232 Continuously asserts the internal RTS signal Internal CTS and DCD signals 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 s
56. STANCE setting by more than the selected amount Alarm Mask ENABLE or DISABLE Range 1 to 100 deviation from NOMINAL RESISTANCE Procedure Adjust the LOW RESISTANCE ALARM deviation to the desired value Note that the LOW RESISTANCE ALARM must be enabled in order to adjust the LOW RESISTANCE deviation IMPORTANT e 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 feature with heating cables that exhibit a variable resistance with temperature Low resistance 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 e 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 w
57. a twisted shielded type with an insulation rating equal to or greater than the highest voltage in the conduit THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 55 77 Follow proper Electrical Code requirements for 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 offset 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 th
58. acers 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 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 15 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 completely off since no heat is required at this temperature to guarantee that the product will not freeze It follows that the amount of heat required by the water line decreases as the ambient temperature increases from 40 C to 10 C theoretically at 15 C the heater output should be approximately 5096 Setting the CONTROL SETPOINT temperature to 10 C and the PROPORTIONAL BAND to 50 C will force t
59. 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 nuisance breaker trips due to cable in rush This feature makes the controller particularly attractive for use with self regulating cables SSR options only Minimum Maximum Temperature Tracking The controller maintains the minimum and maximum temperature values 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 alarming 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 specified Maximum Power Setpoint This feature eliminates the need for low voltage transformers in many applications and can assist in standardization of heating cable types SSR options only Autocycling The controller will momentarily energize the circuit for 10 seconds at a programmable interval
60. and exchange 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 configured correctly for the application If the configuration is correct it may be necessary to return the controller to Pentair Thermal Management 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 8 2 COMMON PROBLEM AREAS 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 symptoms and parameters to check to determine the actual faulty portion of the heat trace circuit 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 correct methods for troubleshooting are outlined as follows
61. ate 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 including 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 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 V IMPORTANT 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 u
62. ated 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 being indicated until a high resistance condition has existed for the duration of the HIGH RESISTANCE ALARM FILTER time Range 0 to 12 seconds Procedure 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 RESISTANCE ALARM 4 FILTER time IMPORTANT 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 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 brownout 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
63. ations interface may be installed in the Control Module A modem version that maintains compatibility with legacy products is available or other industry standard interfaces such as RS 232 and RS 485 may be specified 1 5 CONTROLLER ASSEMBLIES Two standard assemblies are available and stocked at the Factory 1 An SSR version for use in ordinary or Class I 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 Catalog Number Part Number Weight DigiTrace 910 controller in an 8 x 10 FRP enclosure with 910 E1FWL EMR2 10170 001 15 window 2 pole 30 EMR Controls single circuit with 2 pole electromechanical relay Approved for ordinary areas only DigiTrace 910 controller in an 8 x 10 FRP enclosure with 910 E1FWL EMR2 485 10170 015 15 window 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 910 E1FWL SSR2 10170 002 20 window 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 910 E1FWL SSR2 485 10170 016 20 window 2 pole 30 A 277 V SSR Controls a single circuit with
64. ce 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 related to time 14 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 IMPORTANT This feature should be used to reduce the size of a circuit breaker 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 current to an appropriate level The MAXIMUM POWER level may be adjusted to eliminate stepdown transformers lower the effective output wattage of a cable or implement energy management of the heat trace circuit THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 28 77 Range 3 to 33 000 Watts Procedure Ad
65. contained in this document is subject to change without notice CERTIFICATION Pentair Thermal Management certifies that this product met its published specifications at the time of shipment from the Factory LIMITED WARRANTY This Pentair Thermal Management product is warranted against defects in material and workmanship for a period of 18 months from the date of installation or 24 months from the date of purchase whichever occurs first During the warranty period Pentair Thermal Management 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 Pentair Thermal Management The Buyer shall prepay shipping charges to Pentair Thermal Management and Pentair Thermal Management shall 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 Pentair Thermal Management from another country Pentair Thermal Management warrants that the software and firmware designated by Pentair Thermal Management for use with the DigiTrace 910 Controller will execute its programming instructions properly Pentair Thermal Management does not warrant that the operation of the hardware or software or firmware will be uninterrupted or error free WARRANTY EXCLUSION DISCLAIMER The foregoing warranty shall not apply to defects resulting from improper or i
66. could be enabled and non latching temperature alarming used A high temperature condition resulting from a forced on failure of the heating circuit should first be alarmed by the SWITCH FAILURE ALARM See Section 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 IMPORTANT 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 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 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 th
67. ction 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 This section defines the temperature related alarming functions of the 910 controller 5 4 1 TEMPERATURE SENSOR 1 FAILURE ALARM Purpose Enabling TS 1 FAILURE will provide indication of an open or shorted failure of TS 1 Alarm Mask ENABLE or DISABLE Procedure Enable or disable alarming of a failed temperature sensor connected to the TS 1 input as required IMPORTANT e This failure alarm should be enabled if a temperature sensor is connected to the TS 1 input e 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 conditions
68. d 5 5 10 HIGH VOLTAGE ALARM Purpose Alarms voltage levels that are higher than a preset limit for the application Serves as a monitor ofthe 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 VOLTAGE 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 IMPORTANT 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 fthe 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 39 77 5 5 12 LOW RESISTANCE ALARM Purpose Alarms heater resistance levels that have decreased from the NOMINAL RESI
69. d 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 43 77 Alarm Mask ENABLE or DISABLE Range 0 to 999999 off to on transitions Procedure Adjust the CONTACTOR ALARM setting to the desired value Note that the CON TACTOR ALARM must be enabled in order to adjust the CONTACTOR ALARM setting IMPORTANT The CONTACTOR ALARM is only available if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR 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 27 Procedure Enable or disable alarming of a nonvolatile memory failure as desired IMPORTANT The DATA FAILURE ALARM should always be enabled This memory stores all of the controller s configuration and calibration settings and the alarm will only be generated if the microprocessor cannot bypass the failed area of its memory This indicates an internal problem and the 910 should be replaced and returned to the factory for repair 5 6 COMMUNICATIONS SETUP The following section describes the setup parameters that rel
70. e 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 IMPORTANT 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 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 filter time has expired 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 NON LATCHING Procedure Adjust the LATCH TS ALARMS setting to the desired mode latching or nonlatching IMPORTANT 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
71. e alarm output relays to flash or not to flash on an alarm condition whichever 4 Suits the application IMPORTANT f 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 and be extinguished due to a bulb failure or loss of power THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 33 77 e f multiple alarm outputs from different controllers are wired in series 1 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 and 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 rs application IMPORTANT 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 Se
72. e desired value Note that the LOW CURRENT ALARM must be enabled in order to adjust the LOW CURRENT ALARM FILTER time IMPORTANT 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 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 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 374 77 Alarm Mask ENABLE 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 IMPORTANT As the HTC automatically protects itself from overload it would not normally be necessary to enable this alarm This automatic protection can be used effectively to guard against accidental paralleling of heating circuits In rush or cold start currents typically associated with self regulating cables may cause nuisance HIGH CURRENT ALARMS If this is undesirable this alarm should be disabled 5 5 4 HIGH LOAD CURRENT ALARM FILTER TIME SETTING Purpose The HIGH CURR
73. e 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 Ill 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 Pentair Thermal Management representative If the shipping container is damaged or the cushioning material shows signs of stress notify the carrier as well as your Pentair Thermal Management representative Keep the shipping materials for the carrier s inspection 2 3 OPERATOR SAFETY CONSIDERATIONS 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 2 4 OPERATING ENVIRONMENT The operating environment should be within the limitations specified in the 910 Heat Trace Controller Specifications outlined in Appendix A 2 5 INSTALLATION LOCATION The wide ambient operating temperature ra
74. e 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 normally using the terminal block provided at the terminal board IMPORTANT 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 WhiteRed 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 measured 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 accuracy standards of the HTC and the RTD IMPORTANT Ensure you refer to the correct RTD table for the type of RTD you are using Ensure that the TS TYPE setti
75. ed It will be active if the MAXIMUM POWER setting is set below the power output level required for temperature maintenance 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 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 condition 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 IMPORTANT e This is anon latching alarm e This alarm should normally be enabled Currents in this range cannot be considered normal and should be investigate
76. ed then the HIGH TS 1 ALARM temperature 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 0 Platinum or 2 3 wire 100 0 Nickel Iron F Procedure Select the type of RTD that is connected to the TS 2 input IMPORTANT If a 2 wire 100 0 Nickel Iron NI FE RTD is selected then the TS 2 LEAD RESISTANCE must be entered see Section 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 0 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 SETPOINT temperature and force the controller output off if the TS 2 reading exceeds the HIGH TS 2 ALARM temperature setting This is a non latching condition so once the TS 2 reading drops below the HIGH TS 2 ALARM temperature setting the controller will resume normal operation Setting ENABLE or DISABLE 4 Procedure Enable or disable the cutout feature as desired IMPORTANT The TS 2 HIGH LIMIT CUTOUT feature overrides an autocycle test A pending autocycle will be init
77. ensor 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 INPUT g 1 INPUT POWER Be 1 100 277VAC nom 50 60 2 LOAD LiZLINE DUT TRACERCS LOAD L2 NEUTRAL DG LE NEUTRAL THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 67 77 3 1 2 WIRE MODEM OPTION 910 CONTROLLER comm 16 MODEM comm 17 MODEM GROUND 18 DRAIN gt CEN CERT _ MODEM OPTION 3 2 2 WIRE RS 485 OPTION 910 CONTROLLER comm 16 DATA comm 17 DATA GROUND 190 DRAIN 5 amp WIRE RS 485 OPTION C 3 3 RS 232 OPTION COMM 160 RECEIVE DATA COMM 1 G TRANSMIT DATA 3 WIRE RS e3e OPTION C 4 ALARM OUTPUT WIRING C 4 1 USED AS A DRY CONTACT 5
78. er output disconnected Once the cable has been checked it may be reconnected to the controller and power applied 2 8 2 RANDOM START DELAY 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 to 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 13 77 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 s
79. ere is a flow of current from one of the trace supply wires to ground a ground fault condition occurs If a ground fault alarm is present on start up of a new installation it is likely due to a wiring error or damaged cable To verify this condition Check that the heating circuit neutrals return to the controller and are not connected directly to the distribution panel This can be a common problem if the installation is a retrofit 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 an actual ground Va fault condition may exist in the cable IMPORTANT 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 8 3 COMMON ALARMS WHAT TO LOOK FOR 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 different alarm conditions available on the 910 their meanings and po
80. ess resistance either intermittent or continuous may be due to broken or damaged wires or loose terminals 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 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 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 lea
81. f 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 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 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 7 indicate an entry point to a sub menu To enter a sub menu use and A to position the menu item in the display and then press gt Note that the controller remembers where you are in the Configure mode if you temporarily switch to a different mode such as the Monitor mode Switching back to the Configure mode will return you to the same menu item IMPORTANT A few of the controller parameters 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 LO TS 1 LO LOAD HI GFI FE
82. fferent 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 control ona 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 f 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 e The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0 100 band Proportional Control Temperature Band Control Sensor Temperature Duty Cycle Setpoint proportional band 0 Setpoint proportional band 2 50 Setpoint 100 7 2 2 DEADBAND CONTROL FOR USE WITH EXTERNAL CONTACTORS
83. fo pentair com Fax 1 650 474 7215 thermal info pentair com Pentair and DigiTrace are owned by Pentair or its global affiliates All other trademarks are the property of their respective owners Pentair reserves the right to change specifications without prior notice 2001 2013 Pentair THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 77177
84. h 10 stainless steel corrugated RTD10CS RTD10CS 1 0 sheath RTD ambient cable style MONI RTD 200 254741 0 1 C1D1 RTD 100 F to 900 F pipe mounted RTD7AL RTD7AL 2 0 RTD 100 F to 900 F pipe mounted RTD4AL RTD4AL 1 2 OPTIONS Append the following 5 to the end of the standard Model Code to have the option included at the factory Option Code Description 232 RS 232 communications option replace 485 with 232 MDM Modem communications option replace 485 with MDM ALR Red LED pilot light ALG Green LED pilot light Contact your local representative for configurations not listed here THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 8 77 SECTION 2 INSTALLATION AND WIRING Caution Be sure all personnel involved in installation servicing and programming are qualified and familiar with electrical equipment their ratings and proper practices and codes Multiple voltages and signal levels may be present during the installation operation and servicing of this product Do not power the product until the safety provisions outlined in this section have been observed 2 1 INTRODUCTION This section includes information regarding the initial inspection preparation for use and storage instructions for the 910 Series Heat Trace Controller 2 2 INITIAL INSPECTION Inspect the shipping container for damage If the shipping container or cushioning material is damaged it should b
85. he controller s output to be 100 on at 40 C 50 on at 15 and off at 10 5 2 5 DEADBAND SETTING Deadband control mode only Purpose When an HTC equipped with a contactor is used to 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 27 77 Range 2 F to 90 F 1 C to 50 C Procedure Adjust the DEADBAND setting to the desired differential from the desired CONTROL SETPOINT temperature When the control temperature is above the setpoint 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 574 often the contactor will cycle on and off decreasing its opera tional life IMPORTANT See Section 7 2 of this manual an explanation of Deadband Control Note that the MAXIMUM POWER SWITCH CURRENT RATING and CIRCUIT BREAKER CURRENT RATING settings are not available when the HTC is set to Deadband mode typically when switching a contactor
86. he 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 IMPORTANT WARNINGS AND NOTES The following icons are used extensively throughout this manual to alert you to important warnings that affect safety and to important notes that affect the proper operation of the unit Be sure to read and follow them carefully THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 4 77 SECTION 1 OVERVIEW 1 1 INTRODUCTION This manual provides information pertaining to the installation operation testing adjustment and maintenance of the Pentair Thermal Management DigiTrace Model 910 Series Heat Tracing Controller Additional copies of this user manual may be ordered separately through your Pentair Thermal Management representative or online at www thermal pentair com using the document number H56873 1 2 CONTROLLERS COVERED BY THIS MANUAL This document covers the 910 Series Heat Trace Controllers and its available options The information coincides with the specific releases of firmware for the 910 product which are listed on the front page As Pentair Thermal Management releases new firmware to modify or enhance the product significantly new documentation will accompany these relea
87. he control sensor is equal or greater than the CONTROL SETPOINT temperature then the output will have a duty cycle of 0 The controller output 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 IMPORTANT The load shedding fail safe mode is not supported when using proportional ambient contactor control since ambient temperature is being monitored rather than pipe temperature 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 52 77 7 3 LOAD SHEDDING CONTROL MODE 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 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 input Each controller may be associated with one or
88. hown by the text above that key Key Function SHIFT 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 TEST shift ALARM Turns on tracing for 30 seconds When prefixed by the SHIFT key this key switches the console to the Alarm mode 4 BACK shift MONITOR Exits the current menu cancels the new setting when editing 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 gt ENTER shift CONFIG 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 e Increments the value when editing Ww Moves to the next item in a menu Decrements the value when editing a DigiTraCe 222253 STATUS mV SIG BACK M OUTPUT THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 14 77 3 3 LED INDICATORS The console includes eight LED indicators Four LEDs indicate the console operating mode SHIFTed function ALARM MONITOR
89. iated 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 temperature setting can be set regardless of whether the HIGH TS 2 ALARM is enabled THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 30 77 5 2 18 AUTOCYCLE ENABLING Purpose The autocycle function momentarily approximately 10 seconds applies power to the heating circuit at the selected interval It is used to test the integrity of the heating circuit Alarms present at the time of autocycle then become latched and remain active after the completion of the autocycle function 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 be prompted to enter the AUTOCYCLE INTERVAL or AUTOCYCLE UNITS IMPORTANT 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 out
90. ignals are ignored This is the profile used when PROFILE AUTO and an RS 485 communication interface is used e 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 e 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 MODEM 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 stabilize and or synchronize Range 0 00 to 2 50 seconds Procedure Set the amount of delay between the receipt of a message and the controller s response as required IMPORTANT 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 MA 5 7 OPERATOR CONSOLE FUNCTIONS The following features are part of the controller s programming but are only used in conjunction with the Operator Console 5 7
91. ill prevent LOW RESISTANCE ALARMS from being indicated until a low resistance condition has existed for the duration of the LOW RESISTANCE ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW RESISTANCE ALARM FILTER time to the desired value Note that the LOW RESISTANCE ALARM must be enabled in order to adjust the LOW RESISTANCE ALARM FILTER time IMPORTANT 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 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 filter time has expired 5 5 14 HIGH RESISTANCE ALARM Purpose Alarms heater resistance levels that have increased from the NOMINAL RESISTANCE 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 minimizing nuisance alarms created by voltage fluctuations Alarm Mask ENABLE or DISABLE Range 1 to 25096 deviation from NOMINAL RESISTANCE Procedure Adjust the HIGH RESISTANCE ALARM level to the desi
92. ing received e Load shedding and fail safe modes are inactive if a FORCE ON override signal is being received Only the LOW TS ALARMS for temperature sensors used by the TS CONTROL MODE 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 communications 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 from circuits which may be subjected to steam cleaning Setting ENABLE or DISABLE 4 Procedure Enable or disable the load shedding control mode as desired IMPORTANT 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 4 Controller See the appropriate Section of the GCC manual for further details IMPORTANT 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 correspo
93. is written to the controller s nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 49 77 Procedure The IN USE hours accumulator be reset to zero using the Operator Console communicating device IMPORTANT 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 IMPORTANT The PEAK LOAD CURRENT is not displayed on the Operator Console 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 nonvolatile memory once every 24 hours or whenever any maintenance data is reset by the user Procedure The PEAK LOAD CURRENT may only be reset to zero using a communicating device
94. just the MAXIMUM POWER level to the desired value watts Use the TEST Ed TRACING function to observe the power limiting operation IMPORTANT e 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 output 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 IMPORTANT This parameter is part of the TS 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 G
95. kage current THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 57 77 Damaged cable insulation and or moisture present e Moisture in junction box Poor splice or termination e 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 Alarm e 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 Damaged cable 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 intermittent power losses Cause of Alarm Circuit breaker tripped Power line transien
96. key followed by the ALARM key This mode allows you to examine and reset any alarms that may exist Use v A to examine the next previous active alarm 4 1 1 RESETTING ONE ALARM To reset an alarm press gt 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 gt You are prompted for confirmation press to select ALL and press P 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 reading Once the Monitor mode has been selected you may move around in the menu using v 2 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 Monitor Mode Starting Point LO TS 1 29 TS 1 temperature HI TS 1 102 TS 1 temperature TS 1 FAIL ALARM TS 1 temperature LOTS 2 4 C TS 2 temperature HI TS 2 105 C TS 2 temperature TS 2 FAIL ALARM TS 2 temperature CTL TS FAIL ALARM Control tempe
97. 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 RESISTANCE and or the HIGH RESISTANCE ALARMS are enabled Once the controller and the heating cable have been installed the following procedure should be used to determine the 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 V IMPORTANT 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H5687
98. 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 no command is present the controller resumes normal operation If a load shedding command is present the controller will continue to hold its output OFF until one of three conditions occurs 1 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 2 Communications are interrupted between the controller and its communicating device as in the case of a damaged communications wire Approximately 30 seconds after communications ceases the controller will return to normal operation 3 Communications between the controllers and the external communicating device go offline for approximately two minutes as occurs when the 760 Hand Held Programmer is used to communicate with the controller IMPORTANT The controller will return to normal operation if communications between the GCC or external communicating device and the controller is disrupted in any way This will return temperature con
99. n of Proportional Proportional Ambient SSR Proportional Ambient Contactor and Deadband Control algorithms e When using 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 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 or Procedure Using the Operator Console enter the desired text THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 26 77 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 proportional ambient contactor should be
100. nadequate maintenance by the Buyer Buyer supplied software or interfacing unauthorized modification or misuse operation outside of the specifications for the product or improper installation No other warranty is expressed or implied Pentair Thermal Management disclaims the implied warranties of merchantability and fitness for a particular purpose EXCLUSIVE REMEDIES The remedies provided herein are the buyer s sole and exclusive remedies Pentair Thermal Management shall not be liable for any direct indirect special incidental or consequential damages whether based on contract tort or any other legal theory CONDUCTED AND RADIATED EMISSIONS FCC DOC STATEMENT OF COMPLIANCE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reason able protection 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 t
101. nding 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 SETPOINT temperature may be limited to the CONSOLE SETPOINT MAXIMUM value This is a safety feature to prevent users in the field from modifying the CONTROL SETPOINT temperature setting to a dangerous level Range 76 F to 1058 F 60 C to 570 C Procedure Adjust the CONSOLE SETPOINT MAXIMUM temperature value to limit the maximum allowable CONTROL SETPOINT TEMPERATURE that may be set using the Operator Console The CONSOLE SETPOINT MAXIMUM may only be set using a communicating device such as the Model 780 GCC 9000 See the 780 GCC 9000 user manual for the proper procedure IMPORTANT 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 SETPOINT temperature may be limited to the CONSOLE SETPOINT MINIMUM value This is a safety feature to prevent users in the field from modifying the CONTROL SETPOINT temperature setting to a dangerous level Range 76 F to 1058 F 609 to 570 C Procedure Adjust the CONSOLE SETPOINT MINIMUM temperature value to limit the minimum allowable CONTROL SETPOINT TEMPERATURE that may be set using the Operator Console The CONSOLE SETPOINT MINIMUM may only be set using a comm
102. ng Environment 2o 11 12 11 8114 9 2 6 ic prec que eed ex uu ads cuve REOR PARTES TAURI E 10 2 7 S 10 2 8 Initial Power up 2 9 Setup Tor the9 ec edd edes ost 13 Section 3 Operator Console and eene nennt nennt nnne nannan nna 14 Sl Alphanumeric DISplay SA ee dees 14 3 2 Keypad 14 S bED Indiealtofs 15 3 4 Operational 51 5 ot etes ete edet 15 Section 4 O0perator Console Modes inrer iier ener 18 AN Alam J 18 2 ojo RS 19 4 3 Configure ce th te dur 20 Section 5 Configuration Parameter Details 26 oti 26 5 2 Point Setup Parameters peius uan Pede veta 26 5 3 Miscellaneous Setup Paratmet rs ec ee E Eterna ende receiver ie En hi e Y dd 33 5 4 Temperature Sensor Alarms Configuration iastan in aaaea 34 5 5 Other Alarms CORE IQUEALEOfRi
103. ng from the RTD connected to its TS 2 input Depending on the TS CONTROL MODE it may be used to determine the CONTROL TEMPERATURE see Section 6 2 1 above Note If the TS 2 input is not being used then by the controller then the TS 2 TEMPERATURE 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 output F switch is on but no current is present the RESISTANCE will read open circuit IMPORTANT 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 If the controller detects any leakage current in the output circuit it will indicate the level milliamps IMPORTANT minimize nuisance alarms the controller will not report a leakage current of less than 20 mAmps 6 2 7 VOLTAGE Purpose The voltage reading indicates the average circuit voltage being measured by the 910 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 48 77 6 2 8 POWER Purpose Load power provides indication of the average power being consumed by the heat trace cable IMPORTANT The cont
104. ng 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 from the input terminals Connect 100 0 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 0 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 e 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 extended It is not usually a problem to run low signal levels in the same conduit as the power leads even in high power applications as long as the RTD wire is
105. nge of the controller permits installation in most any convenient location Considerations 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 1 Section 18 of the Canadian Electrical Code 2 6 MOUNTING PROCEDURES 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 9 77 The user may want to consider enclosure drain holes in applications where moisture 15 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
106. number of hours since the last time the Controller was reset These parameters may be reset by the user CONTROL TEMP 4 TS1TEMP 4 C TS2TEMP 7 C LOAD 8 9A RESIST 13 260 GFI OmA VOLT 118V POWER 1050 W TEST TRACING DISPLAY TEST MAINTENANCE DATA s Table 4 3 Maintenance Data Sub Menu MINCTLTEMP 2 MAXCTLTEMP 65 C TS1MINTEMP 2 5 1 65 C 152 1 C 5 2 61 POWERACCUM 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 675h END THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 19 77 4 3 CONFIGURE MODE 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 different features Basic and Advanced The Basic Configuration Mode will limit the display to seven of the most commonly modified parameters while the Advanced Configuration Mode presents all of the available parameters Both Configure mode menus contain a parameter called FEATURE MODE which allows the user to specify which Configure mode is to be used IMPORTANT All parameters that are enabled are active with their corresponding settings even i
107. ommended insu lation strip lengths 2 7 1 TEMPERATURE 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 10 77 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 application 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 ex
108. ounding terminals screws are provided for connection of system ground leads Proper system grounding is required for safe and correct operation of the controller s protection features 2 7 6 INPUT POWER The 910 controller may be powered directly from a 100 to 277 Vac circuit The wiring terminal 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 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 12 77 2 8 INITIAL POWER UP 2 9 SETUP FOR THE 910 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 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 controll
109. play segment and all the LEDs of the Operator Console to ensure that they are functioning properly Procedure Select DISPLAY TEST and watch the Operator Console to verify that each display 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 parameters 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 with default values Procedure Select the LOAD DEFAULTS function in the Miscellaneous Setup submenu using Va the Operator Console keypad IMPORTANT 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 47 77 SECTION
110. put on the controller will continue to adjust the output for protection purposes or power limiting 558 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 sensors have failed the HTC will still perform an autocycle f an alarm condition with an alarm filter time greater than 0 appears during the autocycling then the autocycle will be extended 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 heating circuit integrity tests depending on the AUTOCYCLE UNITS specified Range 1 to 240 Procedure Set the AUTOCYCLE INTERVAL to the desired time period e When using proportional ambient contactor mode the CYCLE TIME setting should be less than the AUTOCYCLE INTERVAL otherwise autocycling could affect the duty cycle e f 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 e For the earliest possible alarming of heating circuit problems the AUTOCYCLE INTERVAL should be set to a small value 5 2 20 AUTOCY
111. r Factory User Lo Load Enable Lo Load 1 0 Lo Load Filter Osec Hi Load Disable Hi Load n a 30 0A Hi Load Filter n a 0 sec Hi GFI Enable Hi GFI 20 mA Hi GFI Filter 0 sec GFI Trip Enable GFI Trip 30 mA Lo Volt Enable Lo Volt 90 V Lo Volt Filter 0 sec Hi Volt Disable Hi Volt n a 270V Hi Volt Filter n a 0 sec Lo Resist Disable Lo Resist n a 50 Lo Resist Filter n a 0 sec Hi Resist Disable Hi Resist n a 50 Hi Resist Filter n a 0 sec Nominal Resist n a 6 00 0 Overcurrent Trip n a Enable Switch Fail Enable HTC Reset Disable C B Limiting n a Disable Power Limiting n a Disable Switch Limiting n a Disable Contactor Count Enable Contactor Count 200 000 EEROM Data Fail Enable THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 75 77 Point Setup Sub Menu Parameter Factory User Tag TAG factory ID Switch Control Mode Deadband Prop Band n a 4 F 2 Deadband 5 F 3 Cycle Time n a 10 min Switch Rating n a 30 0 Circuit Breaker n a 30 0 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 n a 010 TS 1 Hi Limit Disable TS 2 Type 1000 Plat TS 2 Lead Resist n a 00 TS 2 Hi Limit Disable Autocycle Enable Autocycle Interval 8 Autocycle Unit
112. rature LO LOAD 0 5A Load current HI LOAD 21 0A Load current HI GFI 52 mA Ground fault current GFI TRIP 77 mA Ground fault current LO VOLT 85V Voltage HI VOLT 140V Voltage LO RESIST 3 38 0 Resistance HI RESIST 9 240 Resistance OVERCURRENT TRIP ALARM Load current SWITCH FAIL ALARM Load current HTC RESET ALARM Time since last reset SWITCH LIMITING ALARM Load current C B LIMITING ALARM Load current POWER LIMITING ALARM Power EEROM DATA FAIL ALARM n a CONTACTOR COUNT 200000 Contactor cycle count THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 18 77 4 2 MONITOR MODE 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 2 Monitor Mode Main Menu CONTROLMODE 4 C TS1TEMP TS2TEMP 7 C only if TS2 is being used LOAD 829A RESIST 13 260 GFI OmA VOLT 118V POWER 1050 POWER 10 4 kW TEST TRACING Turn on tracing for 30 seconds DISPLAYTEST To abort DISPLAY TEST press any key MAINTENANCE DATA Note the indicating a sub menu END 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
113. red value Note that the HIGH RESISTANCE ALARM must be enabled in order to adjust the HIGH RESISTANCE deviation IMPORTANT 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 constantwattage or self THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 40 77 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 e 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 toa relevant level otherwise no HIGH RESISTANCE ALARMS will occur HIGH RESISTANCE ALARMS will only be gener
114. rminal connections approximately 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 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 9 2 REPLACEABLE PARTS There are no user serviceable parts in the 910 series controller or accessories except lamps in optional alarm pilot lights The unit is designed to be modular and easily changed out in the field in a matter of minutes A 910 appearing inoperative should be returned to the nearest Pentair Thermal Management Service Center for service Tampering with the 910 components without approval from Pentair Thermal Management could result in the product s warranty being void THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 60 77 APPENDIX A SPECIFICATIONS Specifications are 4 25 C unless otherwise noted and are subject to change without notice System Ratings Storage Ambient 40 F to 185 F 40 to 85 ApprovalsCSA C US Classification e CLI Div 2 A B C D and Ex nA IIB Zone 2 SSR Version T code T4 Ordinary locations SSR and EMR versions Wiring Terminal Ratings Signal
115. roller calculates load power multiplying the average adjusted voltage reading by the average adjusted current reading 6 3 MAINTENANCE DATA 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 minimum temperatures experienced on a particular tracing circuit for the purposes of troubleshooting 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 CONTROL 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 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
116. s Hours Override Source Remote Load Shedding Disable Miscellaneous Setup Sub Menu Parameter Factory User Temperature Units Version 1 Ext Input Not used Flash Alarm Output Yes Alarm Output N C Language English Passcode 0 Scroll Delay 0 15 sec Load Defaults See user manual Communications Setup Sub Menu Parameter Factory User Protocol HTCBUS HTCBUS Addr factory ID Modbus Addr n a 1 Modbus Sub Addr n a 0 Baud Rate Auto Parity n a None Hardware None modem RS 232 RS 485n a Driver Auto Profile Auto Tx Delay 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 76 77 PENTAIR WWW THERMAL PENTAIR COM NORTH AMERICA EUROPE MIDDLE EAST AFRICA ASIA PACIFIC LATIN AMERICA Tel 1 800 545 6258 Tel 32 16 213 511 Tel 86 21 2412 1688 Tel 55 11 2588 1400 Fax 1 800 527 5703 Fax 32 16 213 603 Fax 86 21 5426 2917 Fax 55 11 2588 1410 Tel 1 650 216 1526 thermal info pentair com cn thermal info pentair com thermal in
117. s 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 F controller for communications purposes IMPORTANT Not all communications interfaces will support the various data rates it is recommended that the setting be set to AUTO The controller will automatically select a BAUD RATE that is compatible with the communications interface installed If BAUD RATE AUTO anda 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 R
118. s 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 IMPORTANT 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 VOLTAGE ALARM FILTER time Range 0 to 12 seconds Procedure Adjust the LOW VOLTAGE ALARM FILTER time to the desired value Note that the LOW VOLTAGE ALARM must be enabled in order to adjust the LOW VOLTAGE ALARM FILTER 57 time Ed IMPORTANT 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 fthe 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 expire
119. sed 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 network to avoid messaging conflicts Either MODBUS protocol must be selected in order to set the MODBUS ADDRESS THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 44 77 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 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 IMPORTANT Since 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 HTC
120. ses 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 communicating 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 thermal pentair com 1 3 PRODUCT OVERVIEW 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 electromechanical 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 large 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
121. sired value Note that the GFI ALARM must be enabled in order to adjust the HIGH GFI ALARM FILTER time IMPORTANT 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 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 TRIP ALARM activated to indicate a ground fault condition Alarm Mask ENABLE or DISABLE Range 20 to 250 mAmps Procedure ground fault tripping is desired enable the TRIP ALARM and adjust the G F TRIP CURRENT to the desired value To disable ground fault tripping disable the alarm Note that the THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 38 77 GFI TRIP ALARM must be enabled in order to adjust the TRIP CURRENT level In order to implement a ground fault trip function ALL NON GROUNDED power conductors must opened upon detection of a ground fault condition IMPORTANT National Electrical Codes may require that all legs of non neutral based power source
122. ssible causes 8 3 1 High TS 1 TS 2 Temperature This alarm appears when the temperature exceeds the HIGH TS ALARM temperature setting Cause of Alarm Alarm temperature setting too close to maintain temperature Flow of 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 temperature setting Cause of Alarm Alarm temperature setting too close to maintain temperature Flow of cold product Empty pipe Damaged wet or missing insulation THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 56 77 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 CONTROL 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 exc
123. t 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 that is applied to the trace circuit to the C B CURRENT RATING setting to protect the upstream heater circuit breaker from tripping THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 58 77 Cause of Alarm e Excessive current caused by in rush current 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 R
124. ternal line voltage pilot light etc Refer to the wiring diagrams in Appendix C for example connection details Dry Contact Alarm and Control Signals 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 diagrams Miscellaneous Signals Terminal No External input 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 114 77 The following tables define the appropriate signal connections for the various types of interfaces RS 485 2 Wire Connections Communication Signal Terminal No Receive transmit
125. trol 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 shedding 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 application requirements If FAIL SAFE MODE is enabled then at least one LOW TS ALARM of a TS used in the T5 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 or zone definition bits of an external communicating device that are to be associated with the load shedding action for the controller must be defined These parameters 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 IMPORTANT Fail safe mode is always disabled if the SWITCH CONTROL MODE is set to either of the two proportional ambient control modes or the T5 CONTROL MODE EXT
126. ue 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 THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 16 77 IMPORTANT Setting the programmed passcode to 0 disables passcode protection e 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 Configuration 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 e Use the SHIFT key followed by the appropriate function key ALARM MONITOR or CONFIG to select the operating mode e Use and A to move around in the menu e Use to enter a new menu enter a new value or select a menu item e Use to exit the current menu or cancel an edit THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 17 77 SECTION 4 OPERATOR CONSOLE MODES 4 1 ALARM MODE The Alarm mode is invoked when you press the SHIFT
127. ues is found in the HTC SETPOINTS Section of the Model 780 GCC 9000 Group Communications Controller Please see the appropriate operating manual for instructions on accessing controller parameters using these devices IMPORTANT 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 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 controller 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 to 1058 F 60 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 IMPORTANT See Section 7 2 of this manual for an explanatio
128. unicating device such as the Model 780 GCC 9000 See the 780 GCC 9000 manual for the proper procedure THERMAL MANAGEMENT SOLUTIONS EN DigiTrace910series IM H56873 04 13 32 77 IMPORTANT The CONSOLE SETPOINT MINIMUM is not displayed 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 IMPORTANT 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 Adjust the setting to the desired temperature units F or IMPORTANT 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 incremented 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
129. whenever any maintenance data is reset by the user Procedure The POWER ACCUMULATOR may be reset to zero using the Operator Console or a 27 communicating device IMPORTANT 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 manufacturer s 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 IMPORTANT Once the CONTACTOR CYCLE COUNTER reaches 999 999 999 it will stop counting 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
130. 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 contact 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 IMPORTANT When used with the INHIBIT FORCE ON feature a contact closure sensed by the EXTERNAL INPUT wilL initiate the INHIBIT FORCE ON mode An open input will cause the controller to revert to normal temperature control operation One possible use of the INHIBIT feature is to use an external device such as a flow meter to provide a contact closure if there is flow in a line As long as the line has adequate flow the heating will be off INHIBITed from operating See Appendix C 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 TEMPBUS will automatically 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 th

DigiTrace 910 Series Heat Trace Controller

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