Chromalox IntelliTrace ITC 1, IntelliTrace ITC 2 Installation & Operation Manual
Installation & Operation Manual
ITC 1 & 2 Circuit
Heat Trace Controller
Line or Ambient Sensing
Ordinary Areas &
Class I, Division 2
PK509-10
0037-75516
June 2018
1
Table of Contents
Section Page
Table of Contents .................................................................................................................................................... 2
Safety Precautions ..................................................................................................................................................3
Introduction .............................................................................................................................................................4
Model Overview ....................................................................................................................................................... 5
Theory of Operation ................................................................................................................................................ 6
Before Powering Up ................................................................................................................................................ 6
Installation ............................................................................................................................................................... 7
Operating the ITC .................................................................................................................................................... 8
HMI (Human – Machine Interface) .................................................................................................................... 8
Main Window ................................................................................................................................................... 8
Navigating the ITC ................................................................................................................................................... 9
The Keypad .................................................................................................................................................... 10
Programming the ITC ............................................................................................................................................ 11
Security Levels ............................................................................................................................................... 11
The Temperature Menu ..................................................................................................................................12
The Current Menu ..........................................................................................................................................12
The Control Menu ..........................................................................................................................................12
The Soft Start Function .................................................................................................................................. 14
The Comms Menu (Communications) ............................................................................................................ 14
The System Menu .......................................................................................................................................... 15
Current Sampling ..................................................................................................................................................19
Alarms ..................................................................................................................................................................19
Dimensions ............................................................................................................................................................ 20
Default Settings ..................................................................................................................................................... 21
Specifications ........................................................................................................................................................ 23
Equipment Ratings ................................................................................................................................................ 25
Field Wiring Considerations .................................................................................................................................. 25
Modbus Wiring Considerations ............................................................................................................................. 25
Customer Wiring .................................................................................................................................................... 26
Modbus Serial Communications ........................................................................................................................... 28
Service Contact Information .................................................................................................................................. 32
2
Safety Precautions
Throughout the intelliTRACETM Setup Guide, these
symbols will alert you to potential hazards. Safety precautions should always be followed to reduce the risk
of fire, electrical shock, injury and even death to persons. Please read all instructions before operating your
intelliTRACE
move power before servicing a circuit. Personnel working with or near high voltages should be familiar with
modern methods of resuscitation. Contact an area supervisor, registered electrician or safety personnel for
more information.
TM
ITC1 or ITC2 Heat Trace Controller.
To avoid electrical shock or injury, always re-
Before working inside the equipment, turn
power off and ground all points of high potential before touching them.
Users should install adequate controls and
safety devices with their electric heating equipment. Where the consequences of failure may
be severe, back-up controls are essential. Although the safety of the installation is responsibility of the user, Chromalox will be glad to
assist in making equipment recommendations.
A disconnect device and circuit breaker should
be provided in the end installation. The installation and proximity for the disconnect device
must satisfy the electrical Authority having jurisdiction for the installation, such as NEC.
Branch circuit protection should be set for 40
amps or lower.
HIGH VOLTAGE is used in the operation of this
equipment; DEATH ON CONTACT may result if
personnel fail to observe safety precautions.
Learn the areas containing high-voltage connections when installing or operating this
equipment.
Be careful not to contact high-voltage connections when installing or operating this equipment.
ELECTRIC SHOCK HAZARD. Any installation involving control equipment must be performed
by a qualified person and must be effectively grounded in accordance with the National
Electrical Code to eliminate shock hazard.
Should the equipment be used in a manner not
specified by Chromalox, the protection provided may be impaired.
3
Introduction
For nearly a century, customers have relied upon Chromalox for premiere quality and innovative solutions for
industrial heating applications. Chromalox manufactures the world’s largest and broadest line of electric
heat and control products.
The intelliTRACETM family of heat tracing products
continues to expand with its latest single or two circuit
controllers the ITC1 & ITC2. These are a complete temperature control and system management solutions for
electrical heat trace applications. They are designed
for industrial applications in ordinary or Class I, Division
2. Groups A,B,C & D hazardous locations.
The intelliTRACETM ITC1 & ITC2 provides the user with
an easy to navigate menu system, continuous critical
parameter monitoring, application flexibility and equipment safety precautions.
The ITC is an ideal solution either Freeze Protection or
Process Temperature control. Whether you have Ambient or Line Sensing or a combination of both, the ITC is
the affordable and complete system for you.
intelliTRACETM ITC Features:
• 1 & 2 Circuit Models
• 100 – 277 VAC, 50/60 Hz
• SSR Control, 40 Amps per Circuit
• PID, On/Off or Manual Control Modes
• Selectable Soft Start Feature
• ModBus Communications
• RTU/RS485 (& 422)
• TCP/Ethernet
• Full Monitoring & Alarms
• High / Low Temperature
• High & Low Current
• GFEP & Sensor Failure
• Programmable Duty Cycle On Sensor Failure
• Alarm Indication & Announcement
• Password Protected Security Levels
• NEMA 4X Fiberglass or 316 SS Wall Mount Enclosure
• LED Indication for Power, Load & Alarm per Circuit
• Front Panel Capacitive Touch Switches
• One or two Sensor Inputs / Circuit – Min, Max & Averaging
• 2 Circuit Ambient control from a single RTD sensor
• High Resolution TFT Display:
• 2 Circuits displayed / screen (on 2 Circuit unit)
• Displayed Parameters: Process Variable, Set
Point Temperature, Control Mode, Soft Start status, Load demand, Alarm Status
Agency Approvals:
• UL, cUL Ordinary Areas, Class I Division 2 areas
• CE
Options:
• Ethernet Communications (TCP/Ethernet or web
server/Ethernet)
• Wireless Communications (Consult Sales)
•
12” x 10” x 8” NEMA 4X 316SS Wall Mount Enclosure
IMPORTANT: To comply with NEC code,
one of the following must apply.
1.
Customer supplied 2 pole GFEP breaker in branch
circuit breaker box upstream of the controller
2.
Requirement shall not apply in industrial establishments where there is alarm indication of
ground faults and the following conditions apply:
a. conditions of maintenance and supervison
ensure that the qualified person(s) service the
installed heater.
b. continued circuit operation is necessary for
safe operation of equipment or process.
4
Model Overview
The ITC series IntelliTRACE Controller is designed
for industrial Heat Trace Line and/or Ambient Sensing applications in Hazardous (Class I, Division 2) or
Non-Hazardous areas. The ITC series controller will
control 1 or 2 circuits and is a wall mounted device
that operates at 100 to 277 VAC and offers the following standard design features: NEMA 4X FG enclosure,
3.5” High Resolution TFT Display with integral display
heater, front panel capacitive touch switches & LED Indication of Power, Load & Alarm.
It also offers PID, ON/OFF or Manual SSR power control, is rated at 40A per circuit in a -40˚F to 104˚F Ambient, employs a Soft Start program and accepts up to 2
RTD sensors per circuit to provide Ambient and/or Line
Sensing type control. When 2 sensors are employed,
the minimum, maximum or average of the two sensor
temperatures may be used to control each circuit.
Table 1
Features / Capabilities ITC1 ITC2
40 Amps/ Loop @ 100 to 277 Volts X X
Number of Circuits 1 2
SSR (Solid State Relay) Control X X
3.5” 320x240 RGB Full color graphic TFT module X X
10” x 8” x 6” NEMA 4X FG Enclosure X X
Soft Start Feature X X
PID, ON/OFF or Manual Control X X
RTU/RS485 & /RS422 ModBus Communications X X
Up to Two RTD Sensors per Circuit X X
Temperature Monitoring and Alarms X X
GFEP Monitoring and Alarms X X
Current Load Monitoring and Alarms X X
Sensor Failure Monitoring and Alarms X X
Three Levels of Security X X
Optional 12” x 10” x 8” (30 x 25 x 20mm) 316 SS Enclosure X X
Optional TCP/Ethernet Communication X X
The ITC2 may also be used as a 2-channel ambient
sensing controller that uses only one RTD to control
both circuits.
Other standard features include: Alarms (1xAC & 1xDC)
for High & Low Current, GFEP (Ground Fault Equipment Protection), High & Low Temperature & Sensor
Failure, ModBus RTU/RS485 & /RS422 Communications. Alarms may be set up to be normally open or
normally closed.
Options Include: TCP/Ethernet Communications, Wireless Temperature Sensing and 316 Stainless Steel Enclosure
Please see Table 1 below for applicable features & capabilities by Model type.
5
Theory of Operation
The detailed set up of the individual circuit parameters
is explained throughout the various sections of this
manual. This Theory of Operation overview is intended
to give a quick summary of how it all works together.
• Parameter setpoints (High/Low Temperature, High/
Low Current & GFEP), Control Modes (Auto or Manual) and operation modes under alarm conditions
(GFEP limit violation & Sensor Loss) are entered for
each circuit. Each circuit is designed to operate independently.
• Active loops are individually tested for 2 seconds
every 2 minutes. During the test, a current load value is updated on the yellow bar located on the Main
Window and a new GFEP current is automatically
and continuously calculated.
• If the Ground Fault (GFEP) limit is surpassed, the
ITC has four options of behavior:
1. Alarm, non-latching – No change in output.
2. Alarm and Trip, non-latching – Ouput goes to
0% (off) while in alarm state.
Note (1&2): Alarm will be cleared when sensed GFEP
is 5mA less than GFEP setpoint.
3. Alarm, latching – No change in output.
4. Alarm & trip, latching – Output goes to 0% (off)
while in alarm state.
Note (3&4): Alarm condition may only be cleared with
a manual reset of the alarm
• Similarly, should a failed sensor condition appear,
the ITC will go into alarm state and display a flashing
sensor error. The ITC will automatically be switched
into Manual mode. The output % may be adjusted
by the user within the SYSTEM MENU Parameter:
“Failed Sensor Output 1 (or 2)”. See Temperature
Sensing & Failed Sensor Output parameters in the
System Menu definitions below.
• To limit inrush current on the overall system, a pro-
prietary Soft Start algorithm is applied during system start-up. This will ONLY occur while the operation mode is set to AUTO. The Soft Start program
will increment the output by 1% every 1 second
until the desired temperature is reached or the output % achieves 100%. After the Soft Start program
completes its cycle, the Auto Control Mode of the
system will return to either PID or ON/OFF Control
Mode, depending what was selected by the user.
The Soft Start Program will not function if the control
mode is set to Manual.
Before Powering Up
Chromalox takes great pride in knowing that we have
provided to you a product of premium quality and
workmanship. We have taken every precaution to ensure that your equipment arrives safe and secure.
However, vibration and temperature changes during
shipping can cause some components to become
loose. Additionally, throughout the life span of this
product, other environmental and application conditions may have affected the mechanical and electrical continuity of several internal components. Therefore, for your safety and overall product performance,
please take the time to familiarize yourself with the
MAINTENANCE, OPERATION, AND INSTALLATION
INSTRUCTIONS technical manual that was shipped
with your control product.
Since it is not uncommon for electrical wiring and mechanical connections to become slightly loosened during shipment, we ask that you pay particular attention
to section 4-5.3:
Wiring and Connections
Check wiring and connections as follows:
a. Inspect wiring for wear, fraying, chipping, nicks, and
evidence of overheating. Repair minor defects with
a good grade of electrical tape, or replace if needed.
b. Inspect for loose electrical and mechanical connec-
tions. Tighten or replace defective crimp-style lugs.
Re-solder loose solder connections. Tighten or replace all loose or missing hardware.
These precautions must be adhered to when the product is received as well as before every season or on an
annual basis, whichever is shortest.
6
Installation
The ITC employs a SSR (Solid State Relay) as a
means to switch the heating load power. Inherently, SSR’s produce heat when operating. Heat
is dissipated at the rear of the ITC through a
heat sink. By design, the ITC must be mounted
in a vertical orientation in order to allow the
heat sink to properly dissipate the heat from
the controller. See Figure 1.
The ITC is shipped with one set of stainless steel
mounting brackets. These brackets were specifically
designed to allow sufficient airflow in and around the
heat sink. The air flow above or below this heat sink
must in no way become restricted. See Figure 1.
To maintain UL compliance, the heat sink must be
inspected every season to confirm that no debris or
objects are in contact with the heat sink. All debris
must be removed from the heat sink fins. High pressure
blasts of clean, dry air or other means which will not
damage the fins are to be used to dislodge all debris
from the fins.
Should the owner decide not to use the provided brackets, mounting of the ITC must incorporate all of the following dimensional safeguards (Refer to Figure 2):
1. Maintain a minimum of 1.5” (3.8 cm) of free air space
on either side of the heat sink (K)
2. Maintain a minimum of 1.8” (4.6 cm) of free air space
directly behind the heat sink (C)
3. Zero air flow restriction above and below the heat
sink.
4. The mounting surface, customer mounting bracket
and fasteners must be of suitable structural design
to support four times the weight of the equipment.
Violating any of the heat sink clearance dimensions or if the equipment is used or mounted in
a manner not specified by Chromalox, the protection provided may be impaired. This could
result in equipment damage, personal injury or
both.
K K
Figure 1
Mounting Surface Considerations
The preferred materials of the mounting surface include metals, concrete or wood products. If the ITC
is to be mounted outdoors, then the metals shall have
corrosion resistant properties and the wood products
shall be treated for outdoor use. If the mounting surface is plaster (drywall), it shall be of the following minimum construction: 1/2”, +/-1/16” (10 mm, +/-2mm) in
thickness and supported by nominal 2” x 4” (50mm
x 100mm, +/-10 mm) studs that are on 16”, +/- 1/2”
(400mm, +/- 10mm) centers. See Dimensions section
for wall mount layout and hole location. Mounting shall
be performed by experienced professionals.
C
C
Heat Sink
Mounting
Brackets
Front
Top View of ITC
Controller
Figure 2
Front
Heat Sink
Right Side View
of ITC Controller
Fasteners
The fasteners shall be of 300 series (304 or 316) stainless steel and they shall be a #8 or #10 (or metric equivalent) bolt or screw configuration. If anchors are to be
used, ensure that they match the fastener specification.
Improper mounting may cause an unsafe condition resulting in equipment damage or failure
which could cause personal injury.
Mounting Surface
7
Operating the ITC
Set Point T
HMI (Human – Machine Interface)
There are three areas on the front panel of the ITC in
which the User may visually receive information or provide input to the controller:
1. LED status indication for Power,
Load & Alarm for each circuit
2. Hi Resolution TFT displays the parameter settings,
alarm type, mode of operation, current load
demand, program menu screen
and menu selection items
3. Capacitive touch keypad
Main Window
In normal operating mode, the main window screen on
the ITC displays the circuit number, set point temperature, process temperature, current load demand, soft
start status, mode of operation, output % and alarm
type for each active circuit.
Below is the Main Window for a 2 Circuit ITC.
Circuit Number
emperature
Process Temperature
Ambient Temperature
Current Load,
Bar Graph & Value
Mode of Operation
& Output % per Circuit
Soft Start Status
8
Auto Mode Type
(PID or On/Off)
Navigating the ITC
Visually, here is how one navigates through the ITC Menus & Parameters:
Security Level 3
Security Level 2
Security Level 1
1. Main Window
Mode
No
Logged?
Yes
Yes
2. Login
No
Correct?
3. Temperature Menu
Temp Setpoint 1
Lo Temp Alarm 1
Hi Temp Alarm 1
Temp Setpoint 2
Lo Temp Alarm 2
Hi Temp Alarm 2
Mode Mode Mode ModeMode
Lo Current Alarm 1
Hi Current Alarm1
GFEP Setpoint 1
GFEP Alarm/Trip 1
Lo Current Alarm 2
Hi Current Alarm 2
GFEP Setpoint 2
GFEP Alarm/Trip 2
5. Control Menu
Auto Control Mode 1
Auto/Man/Off 1
Deadband 1
Autotune 1
Prop. Band 1
Integral 1
Rate 1
Soft Start 1
Manual Offset 1
Curved Double Arrow - continuation path for 1-Circuit Units Only
Auto Control Mode 2
Auto/Man/Off 2
Deadband 2
Autotune 2
Prop. Band 2
Integral 2
Rate 2
Soft Start 2
Manual Offset 2
6. Comms Menu
Baud Rate
Parity
Modbus ID
IP Address
DHCP
7. System Menu 4. Current Menu
Firmware Version
Button Sound
Units
Temp. Sensing 1
Temp. Sensing 2
Failed Sensor
Output 1
Failed Sensor
Output 2
Password Level 1
Password Level 2
Password Level 3
GFEP Alarm/Trip 2
Dashed Parameter Ovals appear on 2-Circuit Units Only
Dashed, Angled Connector - continuation path for 2-Circuit Units Only
Mode
Mode arrow represents pressing the MODE Key
The horizontal security level bars, which are above the
ITC Menu & Parameter navigation map, illustrate the
available menus within that security level. The Main Window is presented when the
Alarm State
Restore to Default
while the operator is at the last available menu screen
within the current security level.
button is selected
9
The Keypad
ENTER
RESET
There are five capacitive touch keys or buttons on the
front panel. The keypad allows the user to select or
change parameters & settings, clear alarms and navigate
throughout the ITC programming areas. See Figure 3
shown below:
MODE UP
DOWN
Figure 3
ENTER
RESET
The function of each key is as follows:
KEY FUNCTION
MODE
UP
DOWN
ENTER
Allows the user to Navigate between
Menus & Main Window
1. Within a Menu, Scroll UP to next Parameter or Setting within that Menu
2. When viewing an adjustable parameter
or setting, increments that parameter
UP to the next available value. For a
quick scroll, push and hold the key.
1. Within a Menu, Scroll DOWN to next
Parameter or Setting within that Menu
2. When viewing an adjustable parameter
or setting, increments that parameter
DOWN to the next available value. For a
quick scroll, push and hold the key.
1. To accept a parameter or setting that
has been entered or changed.
2. Press to accept the change when viewing an adjustable parameter or setting.
3. When in LOGIN Screen, press to advance to next security digit.
Programming the ITC
The ITC is pre-programmed with default parameters and
settings that allow it to function “right out of the box”.
To change any of the parameters or settings on the ITC,
you must access the appropriate menu(s): Temperature
Menu, Current Menu, Control Menu, Comms (communications) Menu or System Menu.
RESET
To access any of these menus, press the
button on the keypad. You will be presented with the
Login screen:
Resets or clears all alarms
10
Press
to advance to the next digit.
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