TraceNet™ TC
Series Control System
TCM18 Panel Installation, Start-Up,
Operating, and Maintenance Guide
Thermon Manufacturing Company
TraceNet™is a registered trademark of Thermon Manufacturing Company.
PN 50316
TCM18 Panel Installation, Start-Up, Operating and
Maintenance Guide
©2014 Thermon Manufacturing Company. All Rights Reserved.
This guide, as well as the firmware described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. The information in this guide is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Thermon Manufacturing Company. Thermon Manufacturing Company assumes no responsibility or liability for any errors or inaccuracies that may appear in this guide.
This information is subject to change without notice. It is recommended that a quick check of the current revision status be done at www.Thermon.com prior to proceeding.
This guide is written and designed at Thermon Manufacturing Company 100 Thermon Drive, San Marcos, TX 78667-0609, USA.
PRODUCT WARRANTY INFORMATION
The seller warrants all equipment manufactured by it to be free from defects in workmanship or material under normal use and service. If any part of the equipment proves to be defective in workmanship or material and if such part is, within 12 months of the date of shipment from sellers factory, and if the same is found by the seller to be defective in workmanship or material, it will be replaced or repaired, free of charge, F.O.B. the seller’s factory. The seller assumes no liability for the use or misuse by the buyer, his employees, or others. A defect within the meaning of this warranty in any part of any piece of equipment shall not, when such part is capable of being renewed, repaired, or replaced, operate to condemn such piece of equipment. This warranty is in lieu of all other warranties (including without limiting the generality of the foregoing warranties of merchantability and fitness for a particular purpose), guarantees, obligations, or liabilities expressed or implied by the seller or its representatives and by statue or rule of the law.
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Contents
Chapter 1: Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 3: Module Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 4: Field and Panel Wiring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 5: Monitoring Heat Tracing Circuit Status
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 6: Accessing Heat Tracing Circuit Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 7: Programming the TCM18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 8: Heat Trace Control and Monitoring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 9: The TCM18 in Process Sensing Applications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter 10: The TCM18 in Ambient Sensing Application
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 11: The TCM18 Data Highway Communication
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Chapter 12: System Start-Up
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Chapter 13: Maintenance
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Chapter 14: Notes
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Chapter 15: More Information
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Appendix A: Trouble Shooting Tips
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix B: Temperature and Current Limits
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Appendix C: Advanced Features of the TCM18 Ambient Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix D: Typical TCM18 Control Applications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Appendix E: Utilities
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Appendix F: Markings for Hazardous Locations (Potentially Explosive Atmospheres)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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1 Introduction
The following serves as a general guide and overview on the installation, startup, operation, and maintenance of a TraceNet TC Series heat tracing control panel utilizing TCM18 control modules. This guide shall be used in conjunction with the project specific control system drawings and any other standard installation instructions/guides provided. In the unlikely event that a conflict or uncertainty arises, contact the Thermon engineering support personnel assigned to this project to clarify.
Note: All personnel should be properly trained and qualified to safely install, service, operate, and program this TraceNet heat tracing control panel as well as to operate the associated heat tracing system.
THE PANEL LOCATION
A wide variety of TraceNet TC Series panel configurations are possible. The TraceNet modules are designed to operate in ambients ranging from -40◦F (-40◦C) to 140◦F (60◦C) and higher. The TraceNet panels can be located in site locations having electrical classifications ranging from ordinary to hazardous. The actual panel markings provided with the panel will detail the design intended specific location requirements.
INITIAL INSPECTION AND HANDLING
Upon receiving the TraceNet TC Series panel, it is important to confirm that the contents of the shipping containers agree with the shipping documents and with the purchase order. Also, it is important to check the shipped container exterior and packing materials for any possible freight damage. Where damage is observed, take photos and notify the carrier as well as your nearest Thermon engineering support center before proceeding further.
After carefully removing the panel from its shipping container, move the panel to its selected location utilizing the pallet base and the securement strapping provided using a lift truck/fork lift. Where lifting eyes are provided on the panel, they should be used when handling.
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Where the panel has external heat sinks to dissipate the heat generated by solid state relay switching, it is recommended that a minimum of 6” (150 mm) of space be allowed between sinks and walls or other panels to minimize heat buildup at the heat sinks. Where heat sinks are present on adjacent panels, allow 12” (300 mm) spacing between heat sinks for sufficient natural air movement.
Adequate door clearance for service work entry and conduit panel entries should be anticipated when establishing the exact panel location. When the panel is located outdoors, a concrete base pad of sufficient height to avoid potential standing water should be constructed.
Once the panel has been properly located, refer to the project specific installation details for the recommended floor mounting as well as wall mounting details.
Once bolted in place, the panel is ready for final configuration, wiring, and site required assembly. Note that the TCM18 control and monitoring module is normally shipped in a separate container to minimize any undue impact stress during shipment. It should be removed from its shipping container again being attentive to any shipping damage that may have occurred during its transit. The TCM18 mounting details are likewise provided in the project specific drawing details.
Note: For installation requirements specific to purged panels, please see Appendix
F. TCM18 Control and Monitoring Modulel
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2 Specifications
The general TraceNet TC Series panel specifications are as given below.
Interior panel operating ambient range |
-40◦F to 140◦F (-40◦C to 60◦C) |
Exterior panel operating ambient range |
-40◦F to 131◦F (-40◦C to 55◦C) |
Ambient storage range |
-40◦F to 158◦F (-40◦C to 70◦C) |
Relative humidity range |
0 to 90% Non Condensing |
Nominal instrument control voltage |
100 to 240 Vac, 50/60 Hz |
Temperature sensor types |
100 Ohm 3 Wire Platinum RTD |
Control temperature range |
-200◦F to 1112◦F (-129◦C to 600◦C) |
Maximum power consumption of TCM18 mod- |
70 Watts |
ule |
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Current ratings in hazardous (classified) locations based on TraceNet TC Series panels for up to 72 circuits are as follows1:
Maximum Panel Exterior |
For: 1 - 36 Circuits |
For: 37 - 72 Circuits |
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Maximum Allowable Average Amps per Relay |
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Ambient (◦C) |
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(Calculated for each side of enclosure)2 |
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40 |
22.2 |
18.0 |
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45 |
21.0 |
16.8 |
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50 |
19.7 |
15.6 |
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55 |
18.3 |
14.3 |
|
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Current ratings in nonhazardous (ordinary) location based on TraceNet TC Series panels for up to 72 circuits are as follows1:
Maximum Panel Exterior |
For: 1 - 36 Circuits |
For: 37 - 72 Circuits |
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Maximum Allowable Average Amps per Relay |
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Ambient (◦C) |
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(Calculated for each side of enclosure)2 |
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20 |
27.0 |
22.7 |
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25 |
25.8 |
21.6 |
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30 |
24.7 |
20.4 |
|
35 |
23.5 |
19.2 |
|
40 |
22.2 |
18.0 |
|
45 |
21.0 |
16.8 |
|
50 |
19.7 |
15.6 |
|
55 |
18.3 |
14.3 |
|
Note 1: Contact the manufacturer for the maximum allowable amps per relay for custom enclosure sizes.
Note 2: Based on factory panel wiring rated for 105◦C.
The TCM18 has the following operating specifications:
Rated supply voltage |
100 to 240 Vac, 50/60 Hz |
Display |
4–7/8” (124 mm) x 1–3/4” (44 mm) LCD STN with LED |
|
backlight |
Touch pad |
Membrane switch stainless steel dome tactile keys |
Control capacity |
Eighteen heat tracing circuits |
Temperature inputs |
Up to two 3 wire 100 Ohm Platinum RTD’s 32◦F (0◦C) per |
|
heat trace circuit |
Temperature control |
-200◦F to 1112◦F (-129◦C to 600◦C) |
range |
|
Communication |
Dual RS485 ports |
Communication |
ModBus ASCII or RTU |
protocol |
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Communication rate |
9600 to 57600 Baud |
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Auxiliary power output |
24 Vdc at 0.5 Amps |
Panel ambient operat- |
-40◦F (-40◦C) to 131◦F (55◦C) |
ing temperature range |
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Storage temperature |
-40◦F (-40◦C) to 158◦F (70◦C) |
range |
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Alarm relay outputs |
|
Option U |
3 sealed dry contact relays rated 0.4A resistive at 24 Vdc |
Option A |
3 sealed dry contact relays rated 0.5A resistive at 100-240 |
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Vac |
Control relay outputs |
Up to eighteen DC outputs each having a sink current capa- |
|
bility of 100 mA 12VDC (24 Vdc optional by programming) |
Control options |
On/Off, On/Off with Soft Start, Proportional, and Ambient |
|
Proportional Control |
LCD heated display |
1-3/4” ( 44 mm) x 4.875” (124 mm) |
TCM18 module |
-40◦F (-40◦C) to 140◦F (60◦C) |
operating temperature |
|
range |
|
The PM6 has the following operating specifications:
Circuit control capacity |
up to six heat trace circuits |
Single pole relay switching capacity |
30 Amperes at 240 Vac* |
Dual pole relay switching capacity |
15 Amperes at 240 Vac* |
Maximum power consumption |
less than 3 Watts |
Relay power connection |
40-Pin header ribbon cable |
Ground/earth leakage test connection |
10-Pin header ribbon cable |
Maximum storage temperature |
185◦F (85◦C) |
Minimum storage temperature |
-40◦F (-40◦C) |
Oper. ambient temp. range |
-40◦F (-40◦C) to 158◦F (70◦C) |
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Power terminal connections |
20 to 6 AWG (0.5 to 10mm2), 630V |
Printed circuit board |
conformally coated |
Alarm |
two 24 Vdc, 350 mA each |
* Rating based on heat sinks installed external to panel. Relay ratings have a reduced rating when sinks are used internal to panel. Higher voltage rating relays are also available as an option.
The RM6 has the following operating specifications:
Maximum storage temperature |
185◦F (85◦C) |
Minimum storage temperature |
-40◦F (-40◦C) |
Oper. ambient temp. range |
-40◦F (-40◦C) to 158◦F (70◦C) |
Terminal connections |
28-12 AWG (0.14 to 2.5 mm2) |
Earth leakage test connection |
10-Pin header ribbon cable |
Relay connection |
40-Pin header ribbon cable |
The RTB6 has the following operating specifications:
Maximum storage temperature |
185◦F (85◦C) |
Minimum storage temperature |
-40◦F (-40◦C) |
Oper. ambient temp. range |
-40◦F (-40◦C) to 158◦F (70◦C) |
Terminal connections |
28-12 AWG (0.14 to 2.5 mm2) |
Maximum RTD capacity |
six |
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6 |
3 Module Connections
Due to its flexible architecture, a variety of TraceNet TC Series panel configurations are available. The specific project drawings should be followed when installing the power supply and field distribution wiring into the TraceNet panel as well as when installing the data highway interface wiring. As an overview and to provide a more general understanding of the inner workings of this panel, the following general connection diagrams are provided.
The TCM18 Connections
The TCM18 is the TraceNet interface to the outside world. It monitors the condition of the heat tracing circuits as well as the heat traced piping temperatures and allows interrogation of heat trace status, alerts the operator to alarm and trip events, and allows the changing of the operating parameters and system configuration.
The TCM18 is designed to be mounted internal to the panel on a panel swing out or on the panel door (if indoors), or behind an instrument access door if outdoors. TCM18 module nominal dimensions are as follows:
Figure 1: TCM18 Control and Monitoring Module
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The TCM18 wiring and connections are located on the rear of the TCM18 module and are described as below:
Figure 2: Wiring and Connection Details on the TCM18
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The RTB6 Module Connections
The RTB6 module allows the connection of six 3-wire 100 Ohm platinum RTD inputs to the TraceNet control system. The RTB6 circuit board is a passive device which communicates the discrete temperature inputs into a 26 pin bundled ribbon cable which then interconnects to a TCM18 module.
The connections within a TraceNet panel for the RTB6 are shown in the illustration which follows.
Figure 3: RTB6 Wiring and Connections
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The PM6 Connections
The PM6 serves as the heat trace power solid state switching module for a TraceNet TCM18 controller. It includes the heater and ground current measurement transformers, solid state heat trace control relays, and the heat dissipating heat sink. This module includes a ground leakage functional test circuit. In addition, alarm and trip output capability to indicating lights on the panel front door are also provided.The module connections for the PM6 are as detailed in the following illustration.
Figure 4: PM6 Wiring and Connections
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The RM6 Connections
The RM6 is a DIN rail mounted six circuit relay interface module for linking to individual solid state or mechanical relays via ribbon cable from the TCM18 controller. The RM6 includes individual terminal strips which allow the interconnection of individually mounted heater and ground current sensing transformers. This module is primarily used where custom current transformers, solid state relays with integral heat sinks, or individual pilot and mechanical relays are to be used. The module connections for the RM6 are as detailed in the following illustration.
Figure 5: RM6 Wiring and Connections
Note: When receiving a new TraceNet TC Series control panel shipment, it is recommended that all module connections within the panel be re-torqued to the recommended tightness levels as provided in the project panel drawing and in Table 1 Chapter 4. Occasionally, it is possible that handling and shipment can loosen some wiring terminations or components cables.
Servicing allowed for removable electrical connectors only when the area is known to be free of explosive atmospheres.
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4 Field and Panel Wiring
For a successful installation of a TraceNet TC Series heat tracing control and monitoring panel, a number of equally critical parts of the system must be installed properly. Areas requiring close attention are the heat trace and insulation, the RTD temperature sensor installation, the distribution of the field RTD and power wiring, and the installation and routing of wiring inside the TraceNet panel.
Note: The heat tracing system installation shall be in accordance with the electrical area classification requirements as well as shall conform to the latest requirements as detailed in applicable heat tracing standards, the local Electrical Code and plant standard practices. Where conflicts arise, contact the project engineer for resolution.
Heat Trace and Insulation Installation
All heat trace circuits and insulation shall be installed in accordance with project installation details provided. In addition, refer to the Electric Heat Tracing Maintenance and Troubleshooting Guide (Thermon Form No. 20745) for general procedures and installation tips.
RTD Installation and Wiring
RTD control sensors should generally be installed on the process lines or in ambient (where ambient sensing is applied) in a location that is most representative of the entire heat trace circuit. In general, it is recommended that the sensors not be located at heat sinks such as pipe supports, pumps, and valves as the control system response needs to be based on the majority of the process line. The RTD control sensor location on the process piping should follow the guidelines detailed in Figure 6.
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Figure 6: RTD Sensor Location
Where limiter RTD sensors are installed on the process piping it should follow the guidelines above. In cases where the limiter is to be installed on the heater itself, it is important to recognize that an offset should be anticipated in the limiter trip value to allow for sensor reading error and overshoot.
As a general rule, field RTD wiring and power wiring should not be routed in the same conduit or proximity in a tray as the temperature signals can become distorted and result in improper readings.
Power Distribution Wiring and Breakers
All field power wiring materials used shall be suitable for the intended service and shall be rated for insulation service temperatures up to and exceeding 221◦F (105◦C) unless otherwise higher values are noted in project specifications. Power supply wiring from the power transformers to the power distribution panel and distribution wiring to the heat trace circuits shall be rated for the heat trace use voltage or higher and sized sufficiently large in wire size to minimize voltage drop. Circuit breakers if not already supplied in the TraceNet panel should be selected based on the heat trace cable type being used, the service voltage, and the circuit current draw characteristics. It is especially important when using self regulating cable to make sure that the circuit breaker response curve type is coordinated with the startup characteristic of the heat trace cable in a cold start condition. All distribution wiring connections should be tightened using a torque indicating screw driver to the levels indicated in Table 1.
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Location of Terminals |
Torque Values (Typical)* |
RTB6 |
5.3 to 7.0 in. lbs. (0.60 to 0.79 N-m) |
PM6 |
12.5 to 13.5 in. lbs. (1.41 to 1.53 N-m) |
Distribution Equipment |
13.2 to 15.9 in. lbs. (1.49 to 1.80 N-m) |
|
|
*Required torque values may vary depending on individual panel designs and size of terminals. Refer to project documentation for additional information.
Table 1: Recommended Torque Values
TraceNet Panel Wiring
TraceNet TC Series panels are configured and prewired into an integrated heat trace control and monitoring system. Clean terminal strips are provided to facilitate the field wiring into the panels. Refer to the project specific panel drawings when installing the field wiring within the panel. Field wiring is conventionally shown by dashed lines. All field power wiring materials used shall be suitable for the intended service and shall be rated for insulation service temperatures up to and exceeding 221◦F (105◦C) unless otherwise higher values are noted in project specifications. All TraceNet components terminal block connections should be tightened using a torque indicating screw driver to the levels indicated in Table 1.
When a panel is rated for IP54 and/or NEMA-4, entries into panels must meet IP54 and/or NEMA-4 ingress protection levels to maintain the environmental rating of the panel.
Serial Communication Wiring
TraceNet TC Series panels may be linked together for communications with a RS485 communication cable at distances up to 4000 feet (300 m.). In addition, a termination module should be used at each end of the RS485 network. The recommended communication cables for use in the RS485 network are as given in Table 2.
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Cables for RS485 Communication
The following data highway cables listed in Table 2 are recommended.
CableType |
Recommended |
120 Ohm, -20 to +60 C 22AWG FHDPE |
Belden 3107A or equal |
insulation PVC outer jacket |
|
120 Ohm, -30 to +80 C 24AWG PE in- |
Belden 9842 or equal |
sulation PVC outer jacket |
|
120 Ohm, -70 to +200 C 24AWG Teflon |
Belden 89842 or equal |
FFEP insulation Teflon FEP outer jacket |
|
Note all these products are designated as 120 ohm impedance for balanced line communication uses.
Table 2: RS485 Cable Types
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5 Monitoring Heat
Tracing Circuit Status
All interfacing to the TCM18 and the heat tracing circuit information is via the dedicated tactile feel membrane touchpad and the companion four line LCD display as shown in Figure 7
Figure 7: TCM18 Control and Monitoring Module Front Panel
On power up, the TCM18 will display the following start-up screen message:
THERMON TCM18
COPYRIGHT 2013
Figure 8: TCM18 Start-Up Screen
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After this start-up message, the TCM18 will immediately proceed to operation in its SCAN MODE.
The TCM18 will operate in a heat tracing circuit SCAN MODE during normal operation. That is, the LCD display will automatically scroll through each enabled heat tracing circuit number, indicating the actual measured temperature and the control set point for maintain temperature on the first two display screen lines. The third display screen line will indicate the heater status (ON % or OFF) and the heat tracing circuit heater current value. The fourth display screen line will indicate any alarm(s) present on the circuit displayed. Where multiple alarm events occur on a circuit, the TCM18 will display only one alarm message at a time until all have been cleared. A typical SCAN MODE screen when the heat tracing circuit is operating normally is as shown below in Figure 9:
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CKT 7 |
TEMP= |
61◦C |
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MAINTAIN TEMP= |
60◦C |
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HEATER ON 80% |
12.0A |
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Figure 9: Typical TCM18 information when in SCAN MODE
Note that the fourth message line on the display screen will be empty as long as there are no alarm or trip conditions present on a given circuit. During SCAN MODE, the TCM18 will sequence through all enabled heat tracing circuits beginning with the first circuit and then loop back to the first circuit after displaying the last circuit and repeat the scanning process. A summary of all possible alarm messages follows.
Message |
|
Explanation |
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RTD FAULT |
The RTD reading is out of the range when the resis- |
||
ALARM |
tance value exceeds 313.7 Ohms or is less than 48.46 |
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|
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Ohms. In this case, either the RTD has not been con- |
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|
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nected or has opened or shorted in service. |
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LOW TEMP |
The temperature being read on this circuit is below the |
ALARM |
value programmed as the lowest temperature allowed |
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before an alarm condition should be reported. |
HIGH TEMP |
The temperature being read on this circuit is above the |
ALARM |
value programmed as the highest temperature allowed |
|
before an alarm condition should be reported. |
HIGH TEMP |
The temperature being read on this circuit is above the |
TRIP |
value programmed as the highest temperature allowed |
|
before a TRIP condition is reported. When a temper- |
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ature exceeds the TRIP level, the event must be AC- |
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KNOWLEDGED and the temperature level must drop |
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below the TRIP set point value before the circuit will |
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re-energize. |
HIGH TEMP |
When there is no TRIP function enabled, the first level |
ALARM |
high temperature alarm setting will automatically clear |
|
when the high temperature alarm condition clears. This |
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event is reported as a HIGH TEMP ALARM. |
HIGH TEMP |
When there is no TRIP function enabled, the sec- |
HHALARM |
ond level higher temperature alarm will automatically |
|
clear when the second high temperature alarm condi- |
|
tion clears. This event is reported as a HIGH TEMP |
|
HHALARM (high-high alarm). |
GND CURR |
The ground/earth leakage current being read on this |
ALARM |
heater (and associated wiring) circuit is above the value |
|
programmed as the highest leakage current allowed |
|
before an alarm event is reported. When there is no |
|
TRIP function enabled, the first level ground/earth cur- |
|
rent alarm setting will automatically clear when the high |
|
ground/earth current alarm event clears. This event is |
|
reported as a GND CURR ALARM. |
GND CURR |
The ground/earth leakage current being read on this |
TRIP |
circuit (and associated wiring) is above the value pro- |
|
grammed as the highest heater leakage current al- |
|
lowed before a TRIP event is reported. When the |
|
ground/earth leakage current exceeds the TRIP level, |
|
the condition must be ACKNOWLEDGED and the leak- |
|
age current level must drop below the TRIP set point |
|
value before the circuit will re-energize. |
PN 50316_0514 |
18 |
GND CURR |
When there is no TRIP function enabled, the second |
HHALARM |
level higher ground/earth leakage current alarm will au- |
|
tomatically clear when the second high ground/earth |
|
current alarm event clears. This event is reported as |
|
a GND CURR HHALARM (high-high alarm). |
LOW AMPS |
The amperage being read on this circuit is below the |
ALARM |
value programmed as the lowest heater operating cur- |
|
rent allowed before an alarm condition is reported. |
HIGH AMPS |
The amperage being read on this circuit is above the |
ALARM |
value programmed as the highest heater operating cur- |
|
rent allowed before an alarm condition is reported. |
|
When there is no TRIP function enabled, the first level |
|
heater operating current alarm setting will automatically |
|
clear when the high heater current alarm event clears. |
|
This event is reported as a HIGH AMPS ALARM. |
HIGH AMPS |
The amperage being read on this circuit is above the |
TRIP |
value programmed as the highest heater operating cur- |
|
rent allowed before a TRIP condition is reported. When |
|
the amperage exceeds the TRIP level, the condition |
|
must be ACKNOWLEDGED and the heater operating |
|
current level must drop below the TRIP set point value |
|
before the circuit will re-energize. |
HIGH AMPS |
When there is no TRIP function enabled, the sec- |
HHALARM |
ond level higher heater current alarm will automati- |
|
cally clear when the second higher heater current alarm |
|
event clears. This event is reported as a HIGH AMPS |
|
HHALARM (high-high alarm). |
CKT FAULT |
A circuit fault condition is reported if during the SELF |
ALARM |
TEST procedure of energizing each circuit, it is deter- |
|
mined that the heater current does not change between |
|
the ON and OFF states. |
GND FAULT |
A ground fault condition is reported if during a TRIP- |
ALARM |
TO-TEST procedure of applying a test leakage current |
|
to each circuit, it is determined that the test leakage |
|
current is not sensed. |
19 |
PN 50316_0514 |
INVALID HI |
This warning message appears when the values that |
TEMP ALRM |
have been programmed into the high temperature |
|
alarm and trip settings are in conflict with maintain tem- |
|
perature and control band. Refer to Appendix A for de- |
|
tails on the limitations on what high temperature alarm |
|
and trip values can be programmed into the TCM18 for |
|
a heat tracing circuit. |
INVALID LO |
This warning message appears when the values that |
TEMP ALRM |
have been programmed into the alarm settings for low |
|
temperature are in conflict with the maintain temper- |
|
ature. Refer to Appendix A for details on the limita- |
|
tions on what low temperature alarm values can be pro- |
|
grammed into the TCM18 for a heat tracing circuit. |
In addition to the individual heat tracing circuit ALARM or TRIP message on the display screen, the “ALARM”, and /or the “TRIP” LED(s) will also begin to flash on the TCM18 front panel as shown in Figure 10. These LED indicators will activate if there are any alarm or trip events recorded on the TCM18 control module. These LEDS will not stop flashing until all conditions have been acknowledged. Once all are acknowledged, the appropriate LED will cease to flash but will remain energized until the condition has actually cleared. These LEDS are also an indication that the three output relays (on the rear of the TCM18 control module) that have been wired to the DCS or other smart monitoring device or to alarm indicating lights or horn are activated.
PN 50316_0514 |
20 |
Figure 10: Common System, Alarm, and Trip LEDS
To acknowledge an ALARM or TRIP event, press the ALARM ACK key on the touchpad. The first alarm condition will be indicated in the INFORMATION DISPLAY. Pressing the ALARM ACK key again will acknowledge the alarm. Repeat this sequence to determine the nature of any additional alarms as well as to acknowledge them. Acknowledged alarms are indicated by the suffix “ACK” appearing on the fourth line of the display screen by the alarm condition being displayed. Acknowledged alarms will continue to be displayed until the alarm condition actually clears. When all alarms have been acknowledged then the ALARM and TRIP LED’s on the controller will cease flashing, but will stay ON until all alarm or trip conditions have cleared.
If a TRIP option has been set on a heat tracing circuit, then all TRIPS for that circuit must be acknowledged before they will clear. When a TRIP event occurs, the TRIP condition must be acknowledged and must clear before automatic control is restored. When a TRIP option has not been selected for a specific type of alarm, the alarm will automatically clear with or without acknowledgement when the alarm condition is no longer present.
21 |
PN 50316_0514 |
6 Accessing Heat Tracing
Circuit Information
To access information on a specific heat tracing circuit, press the appropriate yellow or red key. Pressing these keys will directly access the information and functions associated with that key. As a typical example, press the MAINTAIN TEMP key as shown in Figure 11.
Figure 11: TCM18 Touch Pad
This will result in the display screen response as illustrated below in Figure 12.
PN 50316_0514 |
22 |
CIRCUIT = 7
MAINTAIN TEMPERATURE
MAINT= 49◦C
Figure 12: TCM18 LCD Response
A map of all the information and functions accessible in this manner is summarized
in the following list. |
|
|
||
|
Touch Pad Key |
|
Information Display for Circuit in View Mode |
|
|
|
|
|
|
|
MAINTAIN TEMP |
The display screen provides heat tracing circuit number |
||
|
|
|
and the temperature control set point. |
|
|
CONTROL BAND |
The display screen indicates the heat tracing circuit |
||
|
|
|
number, the temperature control band width, and the |
|
|
|
|
programmed control method being employed. |
|
|
HEATER |
The display screen indicates the operating heater cur- |
||
|
CURRENT |
rent and the programmed default power clamp percent- |
||
|
|
|
age in the event of an RTD fault for the circuit number |
|
|
|
|
displayed. |
|
|
GROUND |
The display screen indicates the measured |
||
|
CURRENT |
ground/earth leakage current for the heat tracing |
||
|
|
|
circuit number displayed and the alarm and trip/high- |
|
|
|
|
high alarm activation values. |
|
23 |
PN 50316_0514 |
CONFIG 1 |
The first parameter line on the display screen indicates |
|
the TCM18 control instructions (ALL ON, ALL OFF, |
|
or BY CKT) for high ground/earth leakage current |
|
trip. The second and third lines indicate the control |
|
instructions for heater operating current and high |
|
temperature trip. An “ALL ON” designation indicates |
|
that the heater circuit will trip on a high value and will |
|
require the operator to press the ACK key and the |
|
condition to clear before the circuit will reset. An “ALL |
|
OFF” setting will leave the circuit in an automatic reset |
|
mode which allows the alarm to disappear when the |
|
condition clears. |
|
Note that the “ALL ON” or “ALL OFF” settings are al- |
|
ways global settings for all eighteen circuits on this con- |
|
troller. A “BY CKT” designation means that an individ- |
|
ual circuit’s trip functions may be set during the circuit |
|
programming process and thus are not global settings. |
CONFIG 2 |
The first parameter line on this display screen indicates |
|
the TCM18 alarm relay configuration options currently |
|
selected (options include “ALARM RLY ALL ALARMS” |
|
which causes the alarm relay to activate on any alarm |
|
or “ALARM RLY TEMP ONLY”) which activates on |
|
temperature alarm events only. |
|
The second parameter line on this display screen in- |
|
dicates whether the relays are configured as “ALARM |
|
RLY NRM CLOSED” or “ALARM RLY NRM OPEN”. A |
|
normally closed relay is of the Form B type and will |
|
open on an alarm event. Relays of this convention |
|
are quite often used when the alarm/trip contacts are |
|
connected to a DCS system or other type of smart |
|
monitoring device. An advantage of this alarm relay |
|
type is that it also naturally creates an alarm if the |
|
controller/system unexpectedly loses power. |
|
A normally open relay is of the Form A type and will |
|
close on an alarm event. This relay convention is often |
|
used when there is light or some warning device like a |
|
horn connected to the alarm relay contacts. |
PN 50316_0514 |
24 |
|
The third parameter line on this display screen indi- |
|
cates the amount of time delay (up to 30 minutes) |
|
that has been programmed in for a High Temperature |
|
Trip event. A value other than “0” for this parameter |
|
indicates the operator has chosen to provide a buffer |
|
to avoid tripping the heat tracing circuit for a short term |
|
higher temperature exposure /operating event. |
|
Note that these CONFIG settings are always global set- |
|
tings for all eighteen circuits on this controller. |
CONFIG 3 |
The parameter line on this display screen indicates the |
|
programmed time period in hours between automatic |
|
heat tracing self test events. The automatic self test |
|
turns each heat trace circuit on and then off to deter- |
|
mine that there is a current reading difference. The |
|
presence of a differential is an indication that the relay |
|
is functional and that the circuit breaker has not been |
|
tripped. Alternatively the parameter line may indicate |
|
that the self test function is “OFF”. |
CONFIG 4 |
The first parameter line on this display screen indicates |
|
the amount of startup delay in minutes for this TCM18 |
|
module. This parameter indicates whether the TCM18 |
|
has a built in delay to “stagger-start” power within a |
|
group of TCM18 modules. |
|
The second parameter line on this display screen |
|
indicates the length of time allowed for each heat |
|
tracing circuit to ramp up to full power during soft start |
|
control with power clamping or when in proportional |
|
control modes. |
|
Note that these CONFIG settings are always global set- |
|
tings for all eighteen circuits on this controller. |
CONFIG 5 |
The first parameter line on this display screen indicates |
|
the first circuit number to be designated for this TCM18. |
|
The TCM18 allows the first circuit number to be pro- |
|
grammed from 1 to 82. This is useful where multiple |
|
TCM18 controllers are present in a common panel. |
25 |
PN 50316_0514 |
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