Chromalox ITASC1D2-EXT Installation Manual
Installation Manual & Set-Up Guide
Ordinary Area
ITAS Ambient Sensing Control Panel
ITAS-EXT Ambient Sensing Extender Control Panel
ITLS Line Sensing Control Panel
ITLS-EXT Line Sensing Extender Control Panel
Hazardous Area
ITASC1D2 Ambient Sensing Control Panel
ITASC1D2-EXT Ambient Sensing Extender Control Panel
ITLS C1D2 Line Sensing Control Panel
ITLS C1D2-EXT Line Sensing Extender Control Panel
PK497-5
0037-75514
June 2018
1
Safety Precautions
IMPORTANT SAFEGUARDS
Throughout the IntelliTrace® 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® ITLS, ITAS, ITLS-EXT or ITAS-EXT Control
Panel.
WARNING
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.
To avoid electrical shock or injury, always remove power before servicing a circuit. Personnel working with
or near high voltages should be familiar with modern
methods of resuscitation. Contact an area supervisor
or safety personnel for more information.
WARNING
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.
Be careful not to contact high-voltage connections when installing or
operating this equipment.
Before working inside the equipment,
turn power off and ground all points
of high potential before touching
them.
ii
Table of Contents
Contents Page Number
Safety Precautions .................................................................................................................................................ii
Table of Contents .................................................................................................................................................iii
Introduction ............................................................................................................................................................ 1
Model Overview ..................................................................................................................................................... 2
Theory of Operation .............................................................................................................................................. 3
Types of Sensing Control ..................................................................................................................................... 4
Pre-Service Storage .............................................................................................................................................. 5
Before Powering Up ............................................................................................................................................. 5
General Panel Notes ............................................................................................................................................ 6
Installation ............................................................................................................................................................. 7
Main Menu Screen ............................................................................................................................................... 8
Temp Setup Menu.. .............................................................................................................................................. 9
Security Levels & Password Screen ................................................................................................................. 10
Temp Setup Menu (Cont.) ................................................................................................................................. 11
Apply Settings Globally .................................................................................................................................... 13
Soft Start Feature .............................................................................................................................................. 13
Load Setup Menu .............................................................................................................................................. 14
Tuning Menu ......................................................................................................................................................... 16
Control Modes: ON/OFF, Autotune & PID ......................................................................................................... 17
Sensor Mapping ................................................................................................................................................ 18
System Properties ............................................................................................................................................. 19
Auto Cycle Feature ............................................................................................................................................ 20
Communications ............................................................................................................................................... 21
Remote Monitoring & System Management ................................................................................................... 21
Alarm Log ........................................................................................................................................................... 22
Active Alarms ..................................................................................................................................................... 23
Clearing Alarms ................................................................................................................................................ 23
Alarm Troubleshooting ..................................................................................................................................... 24
Extension Panels – Connection & Considerations ......................................................................................... 25
Connecting the Extension panel to the Main Panel ......................................................................................... 25
Extension Panel Considerations ....................................................................................................................... 25
Wireless Temperature Sensing ......................................................................................................................... 26
Appendix A ......................................................................................................................................................... 37
Panel Specifications ......................................................................................................................................... 37
Default Settings ................................................................................................................................................ 38
Appendix B ......................................................................................................................................................... 44
ModBus Specification ...................................................................................................................................... 44
Service Contact Information .......................................................................................................................... 106
iii
Introduction
For nearly 100 years, 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 IntelliTrace® ITLS & ITAS Series Multiple Circuit Panels and Extender Panels are a complete temperature
control and system management solution for electrical heat trace applications. They are designed for industrial
applications in Hazardous (Class I, Division 2) or Non-Hazardous environments.
IntelliTrace® provides the user with an easy to navigate touch-screen interface, system parameter monitoring, off
duty preventative maintenance, application flexibility and system customization.
The ITAS and ITASC1D2 provide Ambient Sensing control while the ITLS and ITLSC1D2 provide either Line Sensing control or a hybrid of both Line and Ambient Sensing control.
IntelliTrace® Features:
• 40 Amps/Circuit @ 100 – 600 VAC
• SSR Output Power Control
• 2 to 72 Circuit
• Large Touch Screen HMI
• Integral Control Panel and Circuit Breaker Distribution (non-hazardous areas)
• 1-pole or 2-pole Designs
• Soft Start, On/Off, PID and Manual (Hand) Control
• Modbus RTU/RS485 or TCP/Ethernet Communications
• Full Monitoring & Alarms (Lo/Hi Current & Temperature, Sensor, Transmitter Battery, Communications & GFEP)
• Hazardous (Class I, Division 2) and Non Hazardous Environments
• NEMA 4 Enclosure (Optional NEMA 4X 304 SS)
• UL, cUL Listing (CE available)
Touch Screen Computer:
• 10” on 6 – 72 Circuit Systems and 7” On 2 – 8 Circuit Systems
• 2 or 6 Circuit Circuit Detail Displayed at a Time
• Quick Launch to any 2 or 6 Circuit Group Display
• Remote Desktop Monitoring
• Extremely Intuitive Navigation, User Setting and Operation
• Fully Customizable Circuit Naming and Parameter Programming
Options:
• Powerful and Flexible Sensor Mapping (ITLS, ITLSC1D2 only)
• Enclosure Heater
• Fully Integrated Wireless Temperature Sensing
• IntelliTrace® Supervisory Control (ISC) for Central Command of Multiple Systems
1
Model Overview
The Chromalox line of IntelliTrace® Heat Trace Control
Panels provides a significant amount of application
and feature flexibility.
vide the flexibility for the owner to meet their process
expansion needs. Simply connect the Extension Panel
to its matching ITLS, ITLSC1D2 or ITAS, ITASC1D2
Base Panel and circuit capacity is seamlessly in-
The ITAS and ITASC1D2 are designed for Ambient
Sensing applications while the ITLS and ITLSC1D2 are
creased. The Extension Panels do not have a HMI, but
otherwise are identical.
designed for Line Sensing applications. Additionally,
the ITLS and ITLSC1D2 have the capability to function
as both a Line Sensing control panel and an Ambient
Sensing control panel should the Customizable Sensor
These panels are UL and cUL Listed for Ordinary (Non
Hazardous ITLS/ITAS) and Hazardous (Class I, Division
2 ITLS/ITAS C1D2) Environments. CE is available.
Mapping feature be selected.
Please see Table 1 below for applicable features and
The IntelliTrace® matching ITAS-EXT, ITASC1D2-EXT
capabilities by model type.
and ITLS-EXT, ITLSC1D2-EXT Extension Panels pro-
Table 1
ITLS
Standard Features/Capabilities
Ordinary, Non-Hazardous Area X n/a X n/a X n/a X n/a
Hazardous Area (Class I, Division 2) n/a X n/a X n/a X n/a X
7" Touch Screen HMI (2-4 Loop Versions) X X X X n/a n/a n/a n/a
10" Touch Screen HMI (6-48 Loop Versions)
40 Amps/Loop @ 100-600 VAC X X X X X X X X
Circuits 2, 4, 6, 8, 12, 18, 24, 30, 36, 42, 48 (Expandable to 72 with -EXT Panel)
SCR Control X X X X X X X X
NEMA 4 Enclosure X X X X X X X X
Integral Circuit Panel with Circuit Breakers X n/a X n/a X n/a X n/a
Soft Start Feature X X X X 1 1 1 1
Full Communications X X X X 1 1 1 1
Full Alarm Capabilities X X X X 1 1 1 1
Complete GFEP Monitoring & Alarms X X X X 1 1 1 1
Load Monitoring & Alarms X X X X 1 1 1 1
Sensor Mapping X X X X 1 1 1 1
UL, cUL Listing X X X X X X X X
ITLS
C1D2 ITAS
X X X X n/a n/a n/a n/a
Options
Enclosure Heater X X X X X X X X
Wireless Temperature Sensing X X X X 1 1 1 1
Main Breaker/Disconnect X n/a X n/a X n/a X n/a
Nema 4X 304 SS Enclosure X X X X X X X X
HMI Sunshield X X X X n/a n/a n/a n/a
Panel Weathersheild X X X X X X X X
Heater Power and RTD Terminal Blocks X X X X X X X X
Z-purge system X n/a X n/a X n/a X n/a
Panel Light (on separate breaker) X X X X X X X X
Powered Receptacle (on separate breaker) X X X X X X X X
Copper Ground Bar X X X X X X X X
CE available X X X X X X X X
X - Available as a standard or option for this model
1 - This feature is enabled when paired with matching base panel
n/a - This feature is not available for this model
ITAS
C1D2 ITLS-EXT
ITLS
C1D2-EXT ITAS-EXT
ITAS
C1D2-EXT
2
Theory of Operation
The set-up of the individual and global circuit parameters is explained in the Temp/Load Set-up sections of this
manual. This Theory of Operation overview is intended to give a quick summary of how it all works together.
• Each circuit of the system may be enabled (active) or disabled (inactive). A disabled loop will have no
output and will not map into the common alarm. It will display “Circuit #” and “Disabled” text above
the process temperature. Alarms for disabled circuit will not be monitored or displayed on the screen.
• Each circuit of the system may use unique individual control parameters or the control parameters may
be alike. The Global Settings function facilitates this action.
• The GFEP and Load current are automatically and continuously being calculated. The horizontal orange
bar indicates the average output current for that circuit. The GFEP current value is not displayed on
the screen but its value is compared to the GFEP setpoint. A GFEP alarm condition will occur when
the GFEP current value exceeds the GFEP setpoint value.
• If a ground fault that exceeds the GFEP setpoint value is detected during normal operation and “Trip”
button on the Load Setpoints screen is checked, the output of the defective circuit is set to 0% and
that circuit goes into an alarm condition. If “Trip” button is not selected, the operation of that circuit
continues and that circuit goes into alarm condition. The GFEP alarm may be either Latching or NonLatching.
• During extended periods of time where the output of all circuits are off, such as during warmer seasons, the Auto Cycle feature may be engaged. This feature initiates power to each circuit and checks
for alarms. Each output is tested for one minute within the desired Auto Cycle Interval. The Auto Cycle
feature may be disabled by setting the Auto Cycle Interval time to “0 Hours”.
• To limit inrush current on the overall system, a proprietary 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 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 Control Mode of the system
will either be 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.
• Centralized control of multiple ITAS or ITLS panels is accomplished via the ISC-IntelliTrace Supervisory
Controller.
3
Types of Sensing Control
Ambient Sensing Control
Strict ambient-sensing control utilizes a thermostat or a simple electronic controller which senses the ambient temperature via an RTD, Thermocouple or Bulb & Capillary sensor. This is the simplest type of control as the heating
circuit is energized only when the ambient temperature drops below the setpoint of the controlling device. This is
also known as On/Off control. A relatively large temperature variation around the setpoint is anticipated. Mechanical thermostats are often employed due to their low cost and acceptable accuracy. Multiple heater circuits are
controlled by a singular ambient sensed temperature. This is the least efficient type of control and it is typically
limited to freeze-protection applications.
PASC - Proportional Ambient Sensing Control
Proportional ambient sensing control (PASC) utilizes an electronic controller which continuously compares ambient
temperature and the rate of the change of the ambient temperature to the desired temperature setpoint and regulates
the heater output power accordingly. The result is a smaller temperature variation around the desired setpoint and
a much smoother response to changing weather conditions. Like ambient sensing control, multiple heater circuits
are controlled by a singular ambient sensed temperature. PASC control is therefore significantly more energy efficient than ambient sensing control. PASC control can be employed in a variety of heat trace temperature control
applications but is typically used for freeze protection.
Line Sensing Control
Line sensing control is where each heated section of pipe (or heated surface area) is controlled independently of
other sections of pipe and therefore must have its own controller. Multiple sections of pipe may also be independently
controlled by an electronic multiple circuit control system. The control method may be either proportional or On/
Off control. Each section may have different setpoints and different allowances around the setpoint temperature.
Line sensing control is typically found in process temperature maintenance applications. These applications are
typically more critical and thus demand tighter temperature control. Electronic control is highly recommended over
thermostat control. Like PASC, the pipe surface temperature and the rate at which it is changing is continuously
compared to the setpoint temperature. The controller responds to these variations and regulates the heater output
power accordingly. Mission critical applications should only be managed by controllers which monitor all parameters
and present alarms both locally and remotely via communications or supervisory control means.
4
Pre-Service Storage
If this equipment cannot be placed into service upon receipt, prevent damage caused by impact, harsh environmental
conditions, condensation or liquid ingress. Preferably store in a clean, dry, air conditioned, or ventilated building.
During storage, assemblies should be placed on a firm, level surface to prevent distortion.
Outdoor storage of indoor equipment is not recommended. The covering provided during shipment of indoor assemblies is NOT adequate for outdoor storage.
Cover the equipment to keep it free from dust, dirt, and corrosive elements. The covering must protect the assembly,
but permit adequate ventilation. Blocking placed between the roof of the equipment and the cover will help keep
covering material from restricting the air flow.
If the storage area is subject to humidity and significant temperature changes, energize the anti-condensation heaters provided in the equipment, or add heat from a separate source to prevent condensation inside the equipment.
The internal temperature must be at least 5˚C (9˚F) above the ambient.
If storage temperatures fall below 0°C (32°F), energize the internal equipment heaters provided, or add sufficient
heat from a separate source to keep the internal temperature of the panel to at least 0°C (32°F).
In areas with high humidity, inspect the equipment regularly, and add additional heat if necessary to keep the
equipment dry.
Remove all loose packing, documents, and flammable materials before energizing heating elements.
Heat from a separate source must be removed before the equipment is put into service.
WARNING: Care must be taken that integral control power transformers are not accidentally
back-fed from the heater circuits. Disconnect primary and secondary fuses.
Summer Standby Operation
If equipment is switched off during warm periods, and they are subject to humidity and significant temperature
changes, energize the anti-condensation heaters provided in the equipment, or add heat from a separate source to
prevent condensation inside the equipment. The internal temperature must be at least 5˚C (9˚F) above the ambient.
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 panel.
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:
4-5.3 WIRING AND CONNECTIONS. Check wiring and connections as follows:
a. Inspect wiring for wear, fraying, chipping, nicks, and evidence of over-
heating. Repair minor defects with a good grade of electrical tape, or
replace if needed.
b. Inspect for loose electrical and mechanical connections. Tighten or
replace defective crimp-style lugs. Re-solder loose solder connections.
Tighten or replace all loose or missing hardware.
5
General Panel Notes
1. This panel is designed to UL508A to facilitate NEC and CEC compliance, However it is the responsibility of
installer(s) and end user(s) to make sure that the installation wiring and all equipment, including this panel,
fulfill appropriate national and local electrical code requirements.
2. Incoming and outgoing branch circuit conductors may not be protected by fuses or breakers in this panel.
Consult appropriate national and local electrical codes and device specifications for selective coordination.
3. Protection relays must be set on site according to the requirements of the site engineer’s protection study.
Low-level ground fault protection, if required, should be provided.
4. Consult all applicable instruction manuals.
5. Customer interlocks are provided for use of external shutdown device(s). Interlocks require contacts that open
to trip or shutdown.
6. Contacts are shown in the de-energized state. Controller contacts shown on electrical schematics are internal
to the controller. Most of these contacts are programmable to suit the mode of operation. Consult the appropriate user manual(s).
7. Dashed lines indicate user field wiring connections.
8. The panel installer must ground the panel according to appropriate national and local electrical code requirements.
9. Conduit openings in enclosure are to be user installed, sized and located as required. Hubs or fittings must be
of the same environmental rating as the enclosure to maintain integrity.
10. Unless fitted with an HMI sun sheild, do not place this equipment in direct sunlight.
11. Unless panel is properlly equipped with an enclosure heater for ambient temps below 0°C (32°F), the ambient
temperature outside this panel must be between 0°C (32°F) and 40°C (104°F).
12. If the panel cannot be placed into service upon receipt, an anticondensation heater must be used to prevent
condensation from forming inside the panel. This heater can be user supplied or factory supplied but must be
used to prevent damage to the panel.
13. Dimensions are for reference only, and are nominal unless otherwise specified.
6
Installation
Heat Sink Considerations – Heat Dissipation
The Chromalox ITLS, ITLSC1D2, ITAS & ITASC1D2 Multiple Loop Heat Trace panels employ SSRs (Solid State
Relays) as a means to switch the heating load power. Inherently, SSRs produce heat when operating. This heat
is dissipated through the heat sinks which are typically mounted on the sides of the enclosures. These heat sinks
must be mounted such that the fins are vertically orientation in order to allow the heat sink to properly dissipate the
heat from the controller. The air flow around these heat sinks must in no way become restricted.
To maintain UL/cUL listing, the heat sinks must be inspected
prior to and during every season, or no more than every 12
months, 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.
Servicing Heat Sinks
Adjacent Panel
or Wall
In the rare occurrence that the Power Board assembly, which
includes the Heat Sink, needs to be removed or inspected,
a minimum of 7 inches (18 cm) of clearance is needed to
externally withdraw the assembly from the enclosure.
7 Inches
(18 cm)
Outdoor Applications
Equipment protection from the environment must be carefully considered when installing these systems outdoors.
Both Solar Loading and UV Rays from the sun can impact the performance of these systems.
Solar Loading
The panel ratings, per UL/cUL, are based on operating the panel within the listed Ambient Environmental temperatures and under NO SOLAR LOAD (exposure to direct sunlight).
Therefore, it is highly recommended to install an adequately designed Solar Shield to provide shade across the entire
top of the panel so no solar load is realized. This Shield will also provide some protection to the HMI Touchscreen.
See the appendix for Solar Shield design options offered by Chromalox.
UV Rays
The IntelliTrace® Heat Trace Panels employ an HMI Touch Screen with LED backlit technology. UV Rays are known
to be damaging to these types of HMI touch screens. Chromalox insists on installing HMI Sunscreens in all outdoor
applications to protect the HMI Touch screen from these harmful rays.
See the appendix for HMI Sunscreen design options offered by Chromalox.
Please note that warranties will only be honored if all of the following conditions are met:
1. Suggested options are adequately designed are properly employed
2. These designs must either meet or exceed the designs suggested by Chromalox
3. This Optional Equipment must be installed prior to initial equipment commissioning
7
Main Menu Screen
Circuit Number and Circuit Identification
(1-6, 7-12 for 5 Cir
Sensor Mapping Menu
Active Alarms Menu
Alarm Log Menu
The ITAS/ITLS Touch Screen Computer is extremely user friendly and quite intuitive. Navigation to any other
screens or any 2 or 6 circuit grouping of circuts is accomplished by selecting the blue labeled buttons along the
bottom of the screen or in the upper right or left hand corners.
The main menu screen displays alarm status, circuit number, circuit name, process and set point temperatures,
current load demand, manual/auto control state and output percentage for 2-6 circuits at a time. See Figure 1.
Figure 1
Alarm Status & Type
2-6 Circuit
Navigation
Buttoon (x2)
Process
Temperature
Alarm Status by
2-6 Circuit Grouping
and up Systems
or 1-2, 3-4 for 2-4
Circuit Systems
up to 72 Circuits)
cuit
Temperature
Setpoint
Current Load
Control State
& Output %
Quick Launch to
Temperature Menu
Quick Launch to
Load Setup Menu
Quick Launch to
Tuning Menu
Quick Launch to
Quick Launch to
SystemMenu
Quick Launch to
Quick Launch to
8
Temp Setup Menu
The Temp Setup button at the bottom of the screen is a quick launch to the Temperature Property Sheet which is
simply a series of tabaulated screens. See Figure 2.
Figure 2
Each block contains input cells for the panel operation. For example, temperature and overide controls are located
within the Temp Setup Screen.
Navigation notes:
1. Each screen illustrates 2 or 6 circuits at a time. To make setting changes to circuits beyond the current screen
within the menus, one must select the Circuit Navigation buttons in the upper right or left of screen.
2. For most screens, to save your settings and exit back to the mail screen, select the “X” button in the lower right
corner of the screen.
9
Security Levels & Password Screen
After touching the Temp Setup button, but before the Temp Setup Menu is presented, a pop-up screen requesting a password will appear. See Figure 3:
Figure 3
Initial factory set passwords for the below levels of Security are:
Level Title Code
4. Manager 999
3. Engineering 55
2. Supervisor 20
1. Operator 100
Enter the appropriate password and then hit ENT to continue to the setup screen.
Each of the above Security Levels has predefined accessibility and rights within the programming of the control
panel. They include:
Level Title Accessibility/Rights
4. Manager All customer pages, all passwords and Setpoints editing
3. Engineering All customer pages, Engineering password and All Setpoints editing
2. Supervisor Setpoints, Tuning and Sensor Mapping Tabs & All Setpoints editing
1. Operator Setpoints Tab. Temperature Set Point editing
Changes to specific areas within the menus can only be made once the correct security level code has been
selected.
10
Temp Setup Menu
The Temp Setup Menu tab (See Figure 4) contains input cells for the following settings for each circuit:
• Customized Naming of each Circuit
• Process Temperature Set Point
• High & Low Temperature Alarm Limits
• Maximum allowable GFEP (Ground Fault Equipment Protection) Alarm Limit
• Output behavior, whether Automatically or Manually
• Manual Output Load Percentage (if enabled)
• Circuit Output Override (Enable or Disable Each Circuit)
Additionally, there exists a “Global Setting” within the Circuit# 1 Grid
• Apply Globally Setting
Figure 4
11
Temp Setup Menu Navigation notes:
Apply T
1. Each screen illustrates 2 or 6 circuits at a time. To make setting changes to circuits beyond the current screen
within the Temp Setup Menu, one must select the Circuit Navigation buttons in the upper right or left of screen.
Figure 5 illustrates the input cell identification and location for a single circuit within the Temp Setup Menu:
Figure 5
Circuit Name
Temperature Setpoint
High Temperature
Alarm Limit
Low Temperature
Alarm Limit
emperature
Settings to all
Circuits
Manual Output
Load Percentage
Soft Start
Enable/Disable
Auto/Manual
Output Operation
Enable/Disable
Circuit
12
Definitions for each of the Temp Setup Input Cells:
Name: Customize the Name of this individual circuit or loop
Temp STPT: Process Temperature Set Point (degrees F or C)
HI STPT: High Temperature Alarm Limit (degrees F or C)
LO STPT: Low Temperature Alarm Limit (degrees F or C)
Auto/Manual: Select Auto if you wish the Output behavior to be a function of a PID Algorithm or ON/OFF
Control (See Tuning Tab for selection)
Select Manual if you wish the Output to be driven by a pre-determined Output Percentage.
Enter the desired % output.
Disable Output: Select this check box if you wish to turn off or disable this circuit.
Apply Globally: This allows the user to copy all of the settings or Circuit Parameters from Circuit #1 to all other
available circuits.
Apply Settings Globally
The ITLS/ITAS has a feature which allows the user to apply settings from a single circuit to all of the remaining
circuit within the system. Within Circuit #1 on the Load Setup Menu (See Figure 6), complete the input of the parameters and select the “Apply Glob” button to mirror these settings across all circuits.
Soft Start Feature
These control panels are ideal for controlling heat trace
cable. Certain heating cables exhibit inherent current
inrush in colder temperatures. This inrush can cause
nuisance breaker tripping. To limit inrush current on
the overall system, a proprietary 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 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 control mode of
the system will either be 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.
The default setting of the proprietary soft start feature
for each circuit is “enabled”. However, the soft start
feature may be disabled if so desired by the owner. The
owner has the option to manage the soft start feature
on each circuit individually.
See Figure 5.
13
Load Setup Menu
The Load Setup Menu (See Figure 6) contains input
cells for the following settings for each circuit:
• High & Low Load Alarm Limits
• Trip and/or Latch Enabled/Disabled (Output Permis-
sion) upon GFEP Violation
• Maximum allowable GFEP (Ground Fault Equipment
Protection) Alarm Limit
Figure 6
Additionally, there exists a “Global Setting” within the
circuit# 1 Grid
• Apply Glob. Setting
14
Definitions for each of the Load Setup Menu Input Cells
Load HI Stpt ................. High Current Alarm Limit (Amps)
LoadLO Stpt ................. Low Current Alarm Limit (Amps)
GFEP: ........................... Maximum Allowable Leakage Current setpoint (milliamps)
Trip (GFEP): .................. Enabled: If the GFEP limit is met, the output will be 0%.
Disabled: If the GFEP limit is met, the output is unaffected.
Latch (GFEP): ............... Enabled: If the GFEP limit is met, the alarm condition will remain until it is manually cleared.
Disabled: If the GFEP limit is met, the alarm condition will be cleared once the GFEP vari-
able is less than the GFEP setpoint
Apply Globally: ............. This allows the user to copy all of the settings or Circuit Parameters from Circuit #1 to all
other available Circuits.
Apply Settings Globally
The ITLS/ITAS has a feature which allows the user to apply settings from a single loop to all of the remaining loops
within the system. Within Loop #1 on the Setpoints Tab (See Figure 4), complete the input of the parameters and
select the “Apply Globally” button to mirror these settings across all loops.
15
Tuning Menu
The owner has a choice of how the output is to be operated: Auto, Manual or Off. These selections are made within
the Temp Setup Menu. If “Auto”, or Automatic Control Operation is desired, then the tuning of the automatic control is accomplished via the Tuning Menu.
Figure 7
16
Control Modes: ON/OFF, PID & Autotune
ON/OFF
• Select ON/OFF if you wish the operation of the heat-
ers to be 100% ON when a demand for heat exists
and 0% once the Set Point Temperature of the Process is achieved.
• The Deadband is enabled while in ON/OFF control
mode.
• The Deadband is the temperature range equally
divided above & below the temperature set point,
where the controller will not take corrective action.
o Example: A setting of “10” for the deadband will
result in a deadband that is 5 degrees above and
below the temperature setpoint.
• The deadband is adjustable in 2 degree increments.
It’s default is 10.
PID
• Select PID if you desire PID Control of the load.
• The Proportional Band (P), the Integral (I) & Deriva-
tive (D) are modes of control that work in union to
bring the process variable to setpoint as smoothly
and quickly as possible. They are enabled while in
PID Control mode.
• The P, I & D will be automatically established during
the Autotune procedure (see above).
• Additionally, the P, I & D may all be manually estab-
lished by the user. Great care should be taken when
manually establishing the P, I & D.
• Proportional Band: The temperature band expressed
in degrees within which the controller‘s proportioning action takes place. (Note: The wider the proportional band, the greater the area around the setpoint
in which the proportional action takes place.) This is
sometimes referred to as gain, which is the reciprocal of proportional band.
Autotune
• If the Autotune Feature is selected, then the PID parameters will be calculated and entered by the system once the Autotune function has completed its
demand profile function.
• The Autotune function establishes the individual P, I
& D (Proportional Band, Integral & Derivative) control
modes. These modes help to bring the process variable to the setpoint temperature as quickly as possible.
• In order to properly calculate the P, I & D modes,
the Autotune program requires a 25 degree rise in
sensed temperature after initiating the program. If
within 30 minutes the temperature will not reach its
setpoint, the Autotune algorithm will be canceled
and old PID values will be used.
• Once the Autotune feature is activated, you must not
change the menu page until the Autotune algorithm
is completed. Changing the page will cause the Autotune algorithm to shut down.
• The Autotune function is a one-time algorithm set up
of the P, I & D control modes. Should your process
variables change significantly, it is suggested to that
the Autotune feature be turned off and then reinitiated.
Tuning Tab Navigation Notes:
1. Each screen illustrates 6 loops at a time. To make
setting changes to loops beyond the current screen
within the Tuning tab, one must select the Loop Navigation buttons in the upper right or left of screen.
17
Sensor Mapping
The ITLS and ITLSC1D2 models provide the owner
with customizable sensor mapping. This becomes a
very powerful and desirable feature when the owner
needs added flexibility in controlling the circuit outputs
beyond the standard single sensor input.
1. Sensor Mapping is the assignment of one or more
Sensor Inputs to one or more output circuits.
Sensor (Input) Mapping is accessed via the Sensor
Mapping Menu.
Sensor Mapping
Ambient or Line Sensing, Single Sensor
A single sensor (RTD) may be mapped (or linked) to
multiple output circuits. This allows several circuits to
be controlled by a single sensor.
Minimum, Maximum, Averaging
Several sensors may be mapped to a single output circuit. This allows a single circuit to be controlled by the
minimum, or the maximum or the average temperature
of all of the sensors mapped to that output circuit. This
may be desirable on long runs or zones which realize
varying temperatures or weather conditions at different
times of the day.
Multiple Sensor Mapping
A single sensor may be used independently or combined with other sensors to control more than one circuit.
For Example:
The average temperature of Sensors 1, 3 and 5
is used to control Circuit 1 while simultaneously
the maximum Temperature of Sensor 3, 4 and 5 is
used to control Circuit 2.
Combining Sensing Types
The owner may need to have multiple line and/or ambient sensing control scenarios occurring simultaneously.
For example, these may be occurring simultaneously:
1. Circuits 1, 2, 3, 4, and 5 are all controlled by a single
RTD (Sensor 1) that is sensing the ambient temperature (Ambient Sensing)
2. Circuit 6 is controlled by Sensor Input 2 which is
strapped to a process pipe. (Line Sensing)
Sensor mapping is accomplished within the Sensor
Mapping Menu. See Figure 8.
This does not apply when only 1 Input/Circuit selection
is made from the Order Table.
Figure 8
18
System Properties
Several informative items and general settings are
available within the System Menu.
The System tab is only available to the two highest
owner security levels: Manager and Engineer.
The Autocycle function is reviewed in the Autocycle
Feature section.
Figure 9
Here, one can enter/revise the Facility Name, Date,
Time, Temperature Units, Auto Cycle Interval and Security Codes. The Manager has access to all security
codes while the Engineer has access to only the Engineering Security Code. See Figure 9.
The Security Passwords and the respective rights for
each security level are reviewed in the Security Level
and Password Screen Section.
System Page Definitions
Facility – name of the facility
Units – degree Celsius or Fahrenheit
Autocycle – Autocycle feature. Value of 0 disables it
Number of circuits – number of SSR circuits (not
boards) installed in the panel
Number of RTD boards – Number of RTD boards installed in the panel
Modbus – Modbus feature can be disabled or enabled
to speed up processing and screen update current security level password
Comm Settings – used to select correct Modbus communication parameters (baud rate, parity, stop bits, etc)
IP Address – present IP address of the HMI screen. IP
address can be changed by pushing Comm Settings
button.
Log In – used to change current security level
Log Off – used to log off from the system
Change Password – used to change current security
level password
19
Auto Cycle Feature
During prolonged down time periods, typically during
the summer months, it advisable to intermittently exercise the loops. This exercising of the loops is accomplished via the Autocycle feature.
To enable the Auto Cycle feature, select an Auto Cycle
Interval greater than 0 hours within the System tab.
See Figure 9. The Auto Cycle feature is disabled when
the Auto Cycle Interval equals 0 hours.
Figure 10
On a sequential circuit basis, the Autocycle feature periodically monitors system performance between 1-999
hours. The minimum and maximum values for Current
Load, GFEP and Temperatures are stored. Once the
new high or low value is attained the old value is overwritten and displayed in the Autocycle tab text boxes.
See Figure 10.
This provides a certain level of preventative maintenance of the system as Faults (Alarms) will present
themselves accordingly. Problem areas can be addressed during non-essential operating periods.
It is NOT advisable to engage the Auto Cycle
feature during normal operating periods. The
heating cables will become fully energized for
approximately 2 minutes throughout the Auto
Cycle Interval which could cause undesirable
temperature overshoot.
WARNING:
20
Communications
All changes to the MODBUS settings are achieved via
the COMMS screen. See Figure 11.
The Comms (Communications) screen may be accessed by selecting the COMMS button located at the
bottom of the System screen. The MODBUS Address,
Communication Speed, Parity and Stop parameters
are set within the Communications screen.
For complete communications specification details on
ModBus messaging, Registers and Sensor Mapping,
please reference our “ModBus Wiring and Registry
Map Instructions Document A-60682-04. This is an addendum to the PK497 manual. Go to the ITLS or ITAS
product pages and search in the Technical Resources
Tab at: www.chromalox.com.
Figure 11
Remote Monitoring
& System Management
Users may monitor as well as adjust the System Parameters settings of the panel remotely. The files required for this feature are available to the owner. Due to
the frequent program updates, we ask that you contact
the factory for the most recent release version.
Communication Settings
To display the setting screen, touch (Device/
PLC Settings) from (Peripheral Equipment Settings) in offline mode.
Touch the External Device you want to set from
the displayed list.
Setup Items Setup Description
SIO Type Select the SIO type for communicating with the External Device.
IMPORTANT
In the communications settings, set (SIO Type) correctly according to interface specifications of the Display.
If you select an SIO type that the serial interface does not support, proper operation
cannot be guaranteed.
Refer to your Display Manual for details on the serial interface specifications.
Speed Select the communications speed between the External Drive and the Display
Data Length Select a data length
Parity Select how to check parity.
Stop Bit Select a stop bit length.
Flow Control Select the communications control methond to prevent overflow of transmission and
reception data
21
Alarm Log
The purpose of Alarm Log is to record every alarm
condition with a date and time stamp. This log may be
viewed via the ALARM LOG button at the bottom of the
main screen. See Figure 12.
Alarm condition example: Sensor Error alarm on circuit
18 will be recorded as “11/08/12 – 13:38:48 SENSOR
ALRAM CKT 18”. Every alarm event is saved into a text
file (\Storage Card\log5.txt). Each event is appended to
the file string on a new line.
This table holds up to 750 events (alarms). If the number of entries exceeds 750 then the event that is last
Figure 12
on the list (by date) will be removed from the table. This
process repeats indefinitely. Once an alarm has been
recovered, it can be removed from the list by pushing
the clear recovered alarm button.
To extract these files, one must:
1. Plug a USB flash drive into the USB port located on
the back of the ITLS/ITAS computer. Go to Alarm
Log Screen and push green button on the right of
the screen labeled “Write Alarms to USB.”
Move Upward – moves cursor one position up
Move Downward – moves cursor one position down
Clear All Recovered Alarms – clears all recovered
alarms from the alarm log
Clear Recovered Alarm – clears selected recovered
alarm from the log
Acknowledge All – acknowledge all present alarms
Acknowledged – acknowledge selected alarm
Roll Up – move cursor one position up
Roll Down – move cursor one position down
Write Alarms to USB – saves alarm log into USB thumb
drive
View USB – reads previously recorded alarm log from
the USB thumb drive
22
Active Alarms
Alarms within any 6-circuit or 2-circuit grouping are indicted by RED squares in the left and right panels on
any screen. If the square is GREEN, then no faults exist
within that 6-circuit grouping. Once a fault is realized
within any 6-circuit grouping, one may view the individual alarm circuit or circuits in two different ways:
1. When in the Main Display screen, one may navigate
to the desired 6-circuit grouping via the Navigation
buttons found in the upper right hand or upper left
hand corner. Alarm conditions are illustrated within
each circuit window. Up to three alarm conditions
can be illustrated for any single circuit on the Main
Menu screen.
2.
One may view the status of all fault conditions by selecting the ACTIVE ALARMS MENU button located
at the bottom of the main display screen. To navigate
to the desired 6-circuit grouping, one must press the
Circuit Navigation but-tons found in the upper right
or left corner of any screen. See Figure 13.
Figure 13
Clearing Alarms
Except for a Communications Alarm and a Latched
GFEP Alarm, all other alarms are cleared once the acceptable parameters are achieved.
23
Alarm Troubleshooting
The Alarm Condition, the resultant Output and the Design Behavior for each Alarm type can be found in Table 2
below.
Table 2
Alarm Type Condition Output Design Behavior
HIGH TEMP
LOWTEMP
GFEP
HI CURRENT
(LOAD on Faults
Screen)
LO CURRENT
(LOAD on Faults
Screen)
SENSOR
COMM
Sensed Temp
=> Hi Temp
Setpoint
Sensed Temp
<= Lo Temp
Setpoint
Sensed GFEP
Current =>
GFEP Setpoint
Sensed Load
Current =>
Hi Current
Setpoint
Sensed Load
Current <= Lo
Current
Setpoint
Sensor Open,
Sensor Shorted,
Sensor Fault
Communication
Error
No change Alarm will be cleared automatically when
Sensed Temp < Hi Temp Setpoint
No change Alarm will be cleared automatically when
Sensed Temp > Lo Temp Setpoint
Trip Latch
No No
Yes No
No Ye s
Yes Ye s
Output will switch to Manual
Mode
No change Alarm will clear automatically when
Output will switch to Manual
Mode
Output will switch to Manual
Mode
Output will remain at selected
output %.
Output will go to
0% (OFF) while in
alarm state
Output will remain at selected
output %.
Output will go to
0% (OFF) until
alarm is reset
Alarm will be cleared automatically when
sensed GFEP Current < GFEP Setpoint
The Alarm condition may only be cleared
with a manual RESET of the GFEP Alarm.
Alarm will be cleared automatically when
sensed Load Current < Hi Current Setpoint
Sensed Load Current > Lo Current Setpoint. If your output is turned OFF, GFEP
and Load values will not be updated.
Alarm will clear automatically when the
RTD resistance is between 75.44W -
311.56W. Check if your sensor wire is not
damaged and that it is properly connected
to the Sensor board.
Make sure that the communication cable
that connects the Touchscreen computer
with boards inside enclosure is properly
connected and/or not broken.
Press “RESET ALM” to reset this alarm.
24
Extension Panels
D
Connecting an Extension panel or a
Remote Sensor Panel to the Main Panel
Below is the procedure to connect an Extension or
a Remote Sensor Panel to the Main Panel. The Main
Panel will manage the circuits in the Extension Panel
and the inputs of the Remote Sensor Panel.
Procedure:
1. Turn off the power to the system.
2. In the main panel (the one with a touch screen computer) locate the distribution board (0113-10246)
and verify that jumpers J.16 and J.17 are set in positions 1 & 2.
3. Connect one end of the twisted pair cable into connectors J15.1 (RX+) and J15.2 (RX-) on the distribution board of the Main Panel. Connect the other end
of the twisted pair cable into connector J15.1 RX+
and J15.2 (RX-) on the distribution board of the Extension panel.
Figure 14
Make sure that RX+ is connected to RX+ and RX- to
RX-. (See Diagram Below)
4. Connect the metallic shielding material (see wire
specification below) to the ground of the base panel
Distribution Module. However, DO NOT connect
the metallic shielding to the Extension Panel Distribution Module. (See Diagram Below)
5. If the number of loops needs to be changed, power
up the system and login into the setup menu using
5731 as the password. Go to the “System” tab and
select the desired number of loops and press “OK”.
6. Cycle power to the system.
**Note - a 2 or 4 Circuit Extension Panel may be
added to a 6-48 Circuit system but not vice versa.
Remote Sensor Panel
Main Panel
2,500 FT
(775 M) Max
RX+
Main Panel
Distribution
Module
RX-
GN
Extension Panel or Remote Sensor Panel
Considerations
Environmental influences such as EMI/RFI can compromise the communication signal between the Extension
or Remote Sensor Panel and the Main Pane. The use of
properly designed cable will protect against and minimize
these influences.
Here is a design guide for extension panel wiring:
RS-485 Max. total cable length ........... 2,500 ft (800 M)
RS-485 Wire specification .........T1/E1/DSL compatible
24-AWG shielded cable
Extension Panel
RX+
-
RX
GND
Chromalox uses the following vendor and cable item
as a viable reference:
Example Vendor: ................................................L-com
Typical Specification: ...2 - 120 Ohm (E1) Shielded Pair
Vendor Item Number: .................................... TSC9928
Available at: .............................. http://www.l-com.com
Extension or Remote
Sensor Panel
Distribution Module
25
Wireless Temperature Sensing
No Maintenance Needed.
Overview
Chromalox now provides fully integrated Wireless Temperature Sensing Solutions for Heat Trace applications
in ordinary and hazardous locations.
The components of the Chromalox Heat Trace Wireless
Temperature Sensing system include the IntelliTrace
ITLS or ITAS Series Heat Trace Control Panel and specific industrial wireless transmitters which are paired
with appropriate temperature sensors.
Control Panel
When the wireless temperature sensing feature is selected, the IntelliTrace Control Panel is properly configured at the factory and internally equipped with
an industrial-duty WirelessHART® certified wireless
gateway, antenna and the necessary communication
accessories.
The panel facilitates both wired and wireless temperature sensor inputs and the touchscreen computer HMI
distinguishes wireless circuits from wired ones. Several of the IntelliTrace HMI screens are impacted when
Wireless Temperature Sensing is ordered and enabled
at the factory: The Main Screen and Sensor Mapping
Menu.
Main Menu
On the main menu screen, the alarm status will appear
as BATTERY when the transmitter battery of a wireless circuit is due to be changed. Each wireless circuit
has its own transmitter battery life meter. This provides
three levels of remaining battery life so that you may
properly plan service before it is needed.
Wirless Transmitter
Battery Meter
BATTERY
Battery Life Good.
BATTERY
Battery Life Low.
Plan for Maintenance.
BATTERY
Battery Life Very Low.
Perform Maintenance
Immediately.
26
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