PowerMatch Micro + (PMM+) USER MANUAL
Contents
1. Press the Right button The following window will appear Figure 12 oet min design air temp Ta min 35 C Figure 12 Setting of minimum temperature of the air Tai min Using Up Down buttons set the required temperature value Press the Right button The display window will appear Figure 11 To jump to the next sub menu for setting of the further operating parameters press the Up button The following window will appear Figure 13 oet power time cycle Figure 13 Press the Right button The next display window will appear Figure 14 cet power time cycle 30 minutes Figure 14 Setting of the cycle period corresponding to 100 heater power output Using Up Down buttons set the required cycle period value The possible range is from 30 to 60 minutes Page 10 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY Press the Right button The display window will appear Figure 13 To jump to the next sub menu press the Up button The display window will appear Figure 15 Password gt Figure 15 Press the Right button The display window will appear Figure 16 set password P W 117 Figure 16 The entering of a password enables the temperature parameters to be changed To set the password Using Up Down buttons set the required password Then you can opriate sub menu for chan2. Marking of the Controller Front label with the name and the trade mark of Heat Trace Limited All terminals labeled with terminal number and designation Serial number label to the side of the enclosure Basic operation conditions and supply voltage label fitted to the side of the controller Storage Conditions e Storage temperature range from 20 C to 60 C Relative air humidity at temperature 35 C not less than 80 The air in the storage room shall not contain dust vapours of acids and alkalis or corrosive gases Transportation Conditions The controller must be packaged when transported e Transportation temperature range 20 C to 60 C Relative air humidity at temperature 35 C not more than 90 The controller must not be transported in open conditions Page 13 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY 13 Junction Boxes for Sensors There are two sensors available for use with the PMM Controller an Ambient Air temperature sensor and optionally a Surface Process temperature sensor Sensors are the Pt100 type and should be ordered seperately from the Control unit The standard Pt100 sensors are suitable for temperatures up to180 C Where surface temperature sensors are required to operate at temperatures higher than 180 C a special mineral insulated Pt100 sensor should be specified at the time of ordering Two wire sensors are provided as standard Where the
3. proportional to the calculated current heating power as a percentage of the maximum power One analogue output can be used when smooth heating control is to be provided by means of an external thyristor power controller The second analogue output may for example provide an indication of the heater power by means of a pointer type instrument calibrated for O to 10 V indication Heating power in percent is applied according to the time during which the heating is in the ON condition relative to the total cycle period corresponding to 100 heating power This total cycle period is chosen by the user and set by means of the controller s menu within the range of 30 to 60 minutes 9 Control and Indication Elements The LED indicator is used for information I O 84x48 pixels resolution comprising 6 strings each 14 symbols long Information is entered into the controller by means of 4 control buttons Up T Down Right Reset Return to main menu pw cs During operation the controller displays the main screen The control buttons are used to navigate through the controller s other screens Main Screen Display The main screen displays the current temperature of the two channels the preset temperature control values and the current calculated heating power in percent see Figure 7 Actual Temps Ta 10 C Air Ts 15 C Surface process Power 100 Ta input 35 C Design min Figure 7 Ts inpu
4. sensor is remotely located more than 50 metres from the controller a three wire sensor is required The resistance of the sensor wires should be 100 Ohms maximum Junction boxes and ancillary equipment may be sourced locally if required However it is the responsibility of the installation contractor to ensure that all equipment and components meet the necessary local and international standards and carry the correct approvals and certification to suit the area in which they are installed amp y SENSOR BOX c HEAT i S Sa TYPE JBS000 6911 me sokk x E ai Lama ipsius m Eir SENSOR BOX s ngi 1 OPER WAELE M D B TG HAJ AFG naaa T HEAT a m mm RIS Fig 18 Surface Sensor with DJB9000 EX Junction Box and DESTU Optional For the surface temp sensor the complete unit of sensor DESTU amp DJB9000 carries Fig 19 Image showing how surface sensor Ex e type of protection for haz is protected on pipe by DESTU ardous area use Typical Sensor Configurations Page 14 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY INSTALLATION NOTES PMM Controller Serial No EE ee ee ee ee ee Date Purchased ES Ge ee ee ee ee Date Installed EE ee ee ee ee ee Date commissioned EE EE EE Ee ee ee Installation Details amp Comments Page 15 The Heat Tracing Authority M HEAT TRACE SETTING THE STANDARDS LEADING THE WAY Heat Trace Ltd Mere s Edge Chester Road Helsby
5. Frodsham Cheshire WA6 ODJ U K Telephone 44 0 1928 726 451 Facsimile 44 0 1928 727 846 www heat trace com
6. The and HEAT TRACE SETTING THE STANDARDS LEADING THE WAY POWERMATCH Micro PMM USER MANUAL Heat Trace Ltd Mere s Edge Chester Road Helsby Frodsham Cheshire WA6 ODJ U K Telephone 44 0 1928 726 451 Facsimile 44 0 1928 727 846 www heat trace com HEAT VRAGE SETTING THE STANDARDS LEADING THE WAY Table of Contents Page 1 Controller amp Component Parts Uu 3 2 Connection Methods ie EE Ee ee ee ee ee ee ee ee ee ee 3 3 Temperature Control Methods ccc Re 3 d Controller Specification ee ee ee EER EER Ee RE RR ee ee Re ee ee 4 EE Ee ce OE EE EE eee 5 6 Output circuit ore OE DE BA ED ee EN Oe Ee De ed oe N GP 5 7 Connection of the Controller 5 8 Operating Principles ie ee ee ee ee ee ee ee ee ee ee 7 9 Control and Indication Elements 8 10 Maintenance Operation i ee ee ee ee ee ee ee ee ee ee ee 13 11 Marking of the ControlleF ee ee ee ee ee ee ee ee 13 12 Storage Conditions ee ee ee ee ee ee ee ee ee ee ee ee 13 13 Transportation Conditions ie ee ee ee ee ee ee ee 13 14 Junction Boxes for Sensors uu 14 Page 2 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY 1 Controller amp Component Parts The PowerRMatcu Micro PPM electronic controller is designed for temperature measurement and control of electric heat tracin
7. ace min and Tsutace max the calculated heating power is 0 Yo When the current air temperature is between I surace min and T surface mid the heating power is calculated in proportion to the temperature based on 100 for Tai min and 0 for Tsurace mia For example when the current air temperature is exactly in the middle between Tai min and I surface mid the calculated heating output is 50 POWER 10096 Power 10096 Contraller operates in accordance with algorithm I at this point Fig 5 Algorithm 1 Fig 6 Algorithm 2 Algorithm No 2 Using Ambient air AND Process Temperature Sensors See Fig 6 The process surface temperature sensor is used connected The controller operates in accordance with the Algorithm No 1 but with some additions If the current process surface temperature is less than the preset minimum surface temperature T surface min the calculated heating power is 100 irrespective of the air temperature If the current surface temperature is higher than the preset maximum surface temperature T surface max the calculated heating power is 0 irrespective of the air temperature When the surface temperature is between Tsurtace min and T surface max the Page 7 HEAT TRACE SETTINGTHE STANDARDS LEADING THE WAY controller works according to the Algorithm No 1 Analogue Outputs Two analogue outputs are provided in the controller with outputs in the range 0 10 V The output voltage level of both outputs is
8. erature measurement accuracy Temperature indication accuracy Measurement channels Two channels Air temperature measurement eurface Process temperature Optional Ouitput Relays Two relays Control channel 16A 220VAC Alarm channel 16A 220VAC 220VAC 10 15 50 60Hz Note Sensors are purchased seperately Temperatures in excess of 180 C require MI sensors contact Heat Trace Limited Page 4 HEAT VRAGE SETTING THE STANDARDS LEADING THE 5 Input circuit The controller can simultaneously process two measurement channels Each channel performs temperature measurement by means of a resistive temperature transducer sensor The temperature sensors are type Pt100 Two wire sensors are provided Where the sensor is located more than 50 metres from the controller a 3 wire sensor is required wired as shown in wiring diagram Fig 1 The resistance of the sensor extension wires must be 100 Ohms maximum 6 Output circuit The controlling unit comprises an output circuit of one control relay channel and one alarm relay channel Both relays have a load capacity 16 A 230 VAC 50 Hz Both control and alarm relays have normally open contacts For larger heating loads switching should be via a suitably rated external contactor solid state relay or thyristor drive 7 Connection of the Controller The controller is intended for installation in an electrical panel Mounting is by DIN rail size 4 modules Connecti
9. g circuits The controller provides a facility for temperature measurement by means of one or optionally two measurement sensors The output control optimises the temperature maintenance process The controller is straightforward easy to operate and maintain The component parts of the controller are 2 channel input signal measuring unit The control unit device Power supply unit 2 output relays 1 x load and 1 x alarm e Indication and control elements unit 2 Connection Methods The PMM may be connected to provide temperature control methods Type I or II requiring only the Pt100 ambient sensor or Type II requiring both the Pt100 ambient and line sensors The PMM may be connected for circuit switching by means of a integral 16 amp 230 volt relay see Fig 2 b external suitably rated contactor see Fig 3 C external thyristor or solid state relay drive see Fig 4 3 Temperature Control Methods Process Temperature Accuracy PoweRMatcu Micro can be set up to operate in a number of ways IEC electric trace heating standards define 3 levels of process temperature accuracy Type A Type process is one for which the temperature should be maintained above a minimum point e g freeze protection of water lines Ambient sensing control is usual Type Il A Type Il process is one for which the temperature should be maintained within a moderate band e g temperature maintenance of fuel oil lines Ty
10. ge setting of the temperature parameters To return to the main indication screen of the controller press the Reset button Return to the main menu Page 11 JOT HEU SL JU lod 39s ULE je AS IH HEAT TRACE SETTING THE STANDARDS LEADING THE WAY The controller s indication display diagram the menu structure Figure 16 JOT UW SL juod 35s uue p CLUB 07 DoGEO ULUE dus JE UD ISSp ULU PS SONU LU OE P au Mod PS OTT Wd pJoms d PS lt meds ooejns PS A V lt omerder 1e ULU PS A V lt op oaun Jemod PS A V lt puomssed DSZ 3nduist O SE ANndulre OL BPAMOd DST SL DOT el Sao Jer v Page 12 10 11 12 13 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY Maintenance Operation Maintenance of the controller should be carried out annually Electrical contacts must be verified and dust contamination removed from the terminals of the controller e Verification calibration of the controller should be carried out by simulation of the system sensors and process requirements etc every 2 years During installation and maintenance of the controller the device must be disconnected from the supply network Connection adjustment servicing of the controller must be performed by competent personnel
11. iagram suitably rated external Hi L contactor solid state relay e L AE E 5 2 THYRISTOR Air Sensor Surface Sensor Types 1 amp 2 Type 3 Temp Control Temp Control OPTIONAL Fig4 Wiring Diagram using external thyristor drive Page 6 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY 8 Operating Principles Two algorithms are provided in the controller for heating process control Choice of the actual algorithm is defined by presence absence of the process surface temperature sensor Designations and clarifications Tair min the design minimum air temperature T surface min the design minimum process surface temperature T surface max the design maximum process surface temperature T surface mid the medium value calculated from the design minimum and maximum process surface temperature Algorithm No 1 Using Ambient Air Temperature Sensor Only See Fig 5 The process surface temperature sensor is not used disconnected The controller measures only the air temperature and calculates the percent of the total power required for heating based on the preset temperature parameters air min Tsurtace min ANA Tsutace max When the current air temperature is lower than Tai mi the calculated heating power is 100 When the current air temperature is higher than the medium temperature i e the required process temperature T surface mid Calculated from the preset temperatures Tsur
12. on terminals are shown in Figure 1 13 15 20 z1 23 ze L x L POWER KI re LOAD ALARM RELAY RELAY SENSORS ATA SURFACE Re t WHS TAMAL Oe 100 ARLSLE GLE SIKAMALS Fig 1 Designation of the controller connection terminals e The temperature detectors Rt1 and optionally Rt2 are connected using two wire sensors to terminals 1 amp 3 and 5 amp 7 respectively The resistance of the sensor connection wires must be no more than 100 Ohm e Note air sensor terminals 2 amp 3 and surface sensor terminals 6 amp 7 are linked e Power supply voltage is applied to terminals 13 and 15 e Terminal contacts of control relay K1 and alarm relay K2 are 20 21 and 23 24 respectively e Analogue output signals in the voltage range 0 10 V are available at terminals 9 10 and 11 12 Page 5 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY Connection Wiring Diagrams OPTIONAL SENSOR FAILURE DS ATOR Heating Circuit OFF Air Sensor Surface Sensor Types 1 amp 2 Type 3 Temp Control Temp Control OPTIONAL Fig 2 Wiring Diagram using Integral 16 amp 230 volt Relay OPTIONAL SENSOR FAILURE INDICATOR Heating Circuit OFF EI LL HEATER _ MES HEATER LOAD CONTACTOR OPTIONAL SENSOR X FAILURE INDICATOR Heating Circuit OFF Air Sensor Surface Sensor Types1 amp 2 Type 3 Temp Control Temp Control OPTIONAL EE Fil 23 E z HEATER A Lama Fig3 Wiring D
13. pe Ill A Type Ill process is one for which the temperature should be controlled within a narrow band e g maintenance of temperature sensitive materials such as chocolate Page 3 HEAT VRAGE SETTING THE STANDARDS LEADING THE WAY POWERMATCH Micro can be set up to provide Types I II or Ill control methods Type I Type I control is achieved by means of the PT100 ambient sensor only Large blocks of power may be controlled by means of a single device Energy savings compared with a traditional on off air thermostat will typically be 80 90 Type Il Type Il process control may also be achieved by means of the PT100 ambient sensor only Heating cables should be applied to the pipework such that heating loads approximate heat losses when the ambient temperature is at the minimum design level Type Ill A Type Ill process control may be achieved by means of both the PT100 ambient and line sensors The line sensor should be located on a heated line having no flow This may need to be a dummy pipe dead leg Heating cables should be applied to the pipework such that heating loads closely match heat losses this means that heating cables may need to be spiralled One PowerRMatcu Micro will be required for each different line temperature required Fewer controllers will be required compared with the use of traditional line controls 4 Controller Specification Temperature control range From 60 C to 500 C see note below Temp
14. t Design surface proc setting of Control parameters P 1 bmenu will be displayed Figure 8 Set surface temperature Figure 8 From this sub menu you can go to a display window designed for setting the process temperature parameters of the heating surface Page 8 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY Setting of the process alarm levels Press the Right button The following window will appear Figure 9 Lo temp alarm set point Ts min 10 C Figure 9 Setting of minimum temperature of the heating surface T surface min Using Up Down buttons set the required temperature value Press the Right button The following window will appear Figure 10 Hi temp alarm set point Ts max 10 C Figure 10 Setting of maximum temperature of the heating surface T surface max Using Up Down buttons set the required temperature value Press the Right button The display window will appear Figure 7 To jump to the next sub menu for setting of the further operating parameters press the Up button The following window will appear Figure 11 Set min air temperature gt Figure 11 From this submenu you can go to an display window designed for setting the minimum ambient air temperature below which 10096 power must be applied by the heating system Page 9 HEAT TRACE SETTING THE STANDARDS LEADING THE WAY
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