DigiTrace T2000 Heat Trace Controller

Transcription

1 DigiTrace T2000 Heat Trace Controller INSTALLATION, OPERATING, AND MAINTENANCE MANUAL CM 2000 CM AC 2000 AC Control Module, Control Module, Alarm/Communications Interface Alarm/Communications Interface, Firmware versions up to V1.4X Firmware versions up to V2.35 Firmware versions up to V3.1X T2000 ALARM/COMMUNICATIONS INTERFACE RECEIVE CARRIER REQ TO SEND ALARM TRANSMIT OUTPUT ALARM TRANSMIT RECEIVE ADDRESS TEMP CURRENT SET PT CONTROL MODULE F T2000 CM 2000 OUTPUT ALARM TRANSMIT RECEIVE ADDRESS TEMP CURRENT SET PT CONTROL MODULE F T2000 CM 2000 OUTPUT ALARM TRANSMIT RECEIVE ADDRESS TEMP CURRENT SET PT CONTROL MODULE F T2000 CM 2000 OUTPUT ALARM TRANSMIT RECEIVE ADDRESS TEMP CURRENT SET PT CONTROL MODULE F T2000 CONTROL MODULE T2000 CONTROL MODULE T2000 CONTROL MODULE T2000 CONTROL MODULE T2000 CONTROL MODULE T2000 CM 2000 CM / 81

2 CONTENTS Introduction...4 Certification...4 General Instructions...4 Limited Warranty...4 Conducted and Radiated Emissions FCC/DOC Statement of Compliance...4 Technical Support...4 Important Warnings and Notes...5 Section 1 Overview Introduction DigiTrace T2000 Components External Programming Devices Control Module Overview AC Card Overview Component Ordering Guide Section 2 Installation and Wiring Introduction Initial Inspection Operating Environment Installation Location Mounting Procedures Wiring Initial Power Up Section 3 Control Module Programming and Configuration Introduction and Initial Power-Up Front Panel Features Displayed Alarm Indicators Point Setup Parameters Alarm Settings Section 4 Control Module Monitored Parameter Details Introduction Analog Readings Maintenance Data Section 5 Control Module Control Modes Introduction Switch Control Modes Load Shedding Control Mode Ambient Temperature Control (ATC) Mode Section 6 Control Module Troubleshooting Operator Checks Common Problem Areas Common Alarms What to Look For Section 7 AC Programming and Configuration Introduction Initial Configuration Input/Output Ports Operational Configuration Remote Data Access AC Alarms What to Look For / 81

3 Section 8 Maintenance Operator Maintenance Replaceable Parts Appendix A Specifications...60 Appendix B DigiTrace T2000 HTC Component Wiring Diagrams...63 B.1 Control Module / CT 2000 Contactor Wiring Diagram B.2 Control Module / CT 2000-HAZ Single Pole SSR Wiring Diagram B.3 Control Module / CT 2000-HAZ Two Pole SSR Wiring Diagram B.4 AC 2000 Alarm / Communications Interface Card Wiring Diagram B.5 AC Alarm Communications Interface Card Wiring Diagram B.6 AC Local Port RS-232 Connections B.7 External Alarm and Warning Relay Connections B.8 CR 2000 Card Rack Terminal Assignments B.9 CR 2000 Rev. A Card Rack Terminal Assignments B.10 CR Card Rack Terminal Assignments Appendix C Label Details...72 Appendix D Card Rack Dimensions...73 Appendix E Load Shedding Operations...74 E.1 AC LOAD SHEDDING SEQUENCE E.2 CONTROL MODULE LOAD SHEDDING SEQUENCE Appendix F 100 W PLATINUM RTD Table...76 Appendix G Factory Default / Configuration Sheets...77 G.1 CM 2000 Control Module V2.35 Configuration Sheet G.2 CM Control Module V3.1X Configuration Sheet / 81

4 INTRODUCTION Installation and Maintenance Instructions for: CM 2000 Control Module, firmware versions up to and including V2.35 CM Control Module, firmware versions up to and including V3.1X AC Alarm/Communications Interface, firmware versions up to and including V1.4X Notice: The information contained in this document is subject to change without notice. CERTIFICATION Pentair Thermal Management certifies that this product meets its published specifications at the time of shipment from the factory. GENERAL INSTRUCTIONS Pentair Thermal Management strongly recommends careful consideration of the following when specifying and installing the DigiTrace T2000 HTC. Before installing a unit, the Installation and Maintenance instructions provided with the unit must be read and understood. To avoid damaging the unit, never exceed the limits stated in the literature and on the labels. Use a back-up unit for applications where damage to a primary unit could endanger life, limb or property. A high or low limit switch is necessary for applications where dangerous runaway conditions could result. Adjustable ranges must be selected so that incorrect, inadvertent or malicious setting at any range point cannot result in an unsafe system condition. Install units where shock, vibration and ambient temperature fluctuations will not damage the unit or affect operations. Orient the equipment so that moisture does not enter the enclosure via the electrical connection. The unit must not be altered or modified after shipment. Consult Pentair Thermal Management if modification is necessary. Periodic testing is necessary for critical applications where damage to unit could endanger property or personnel. Electrical ratings stated in literature and on labels must not be exceeded. Overload on a switch can cause damage, possibly on the first cycle. Wire the unit according to local and national electrical codes. Use only Pentair Thermal Management authorized replacement parts and procedures. LIMITED WARRANTY Pentair Thermal Management limited standard warranty applies to all DigiTrace products. You can access the complete warranty on CONDUCTED AND RADIATED EMISSIONS FCC/DOC STATEMENT OF COMPLIANCE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. This equipment does not exceed Class A limits for radio emissions as set out in Schedule V to VIII of the Radio Interference Regulations of Communication Canada. Cet apparel respecte les limites de bruits radioelectriques applicables aux appareils numeriques de Classe A prescrites dans la norme sur le materiel brouilleur: Appareils Numeriques, NMB- 003 edictee par le Ministre des Communications. 4 / 81

5 TECHNICAL SUPPORT IMPORTANT WARNINGS AND NOTES Local Representatives Contact your local Pentair Thermal Management representative for help. For the most up-to-date and complete listing, go to click Heating > Customer Support, select your region, click Go, choose an application, enter your postal code if prompted, and click Find. Contact information for your local representative will appear. FAQ For Frequently Asked Questions, go to click Heating > Technical Support, and select FAQ. Local Representatives can questions to The following icons are used extensively throughout this manual to alert you to important warnings that affect safety and to important notes that affect the proper operation of the unit. Be sure to read and follow them carefully. 5 / 81

6 SECTION 1 OVERVIEW 1.1 INTRODUCTION 1.2 DIGITRACE T2000 COMPONENTS This manual provides information pertaining to the installation, operation, testing, adjustment, and maintenance of all the components of the DigiTrace T2000 Series Heat Tracing Controller (HTC). A DigiTrace T2000 HTC is made up of at least one card rack, one alarm/communications interface card, and one or more control modules, each with its own current transformer and switching module. The information coincides with the specific releases of firmware for the CM 2000, CM and the AC components which are listed on the cover page. As Pentair Thermal Management releases new firmware to significantly modify or enhance any of these components, new documentation will accompany these releases. To ensure that you are using the correct documentation for your particular version of DigiTrace T2000 HTC, compare the firmware version number of each component against the version numbers listed on the front page of this manual. As subsequent changes are made, supplements to this document will be included in manuals shipped after the firmware is released. Supplements will make specific reference to the operational or functional changes. Additional copies of this manual may be downloaded from the Literature section of The DigiTrace T2000 HTC is made up of a number of modular components, allowing the ultimate in design flexibility. Figure 1-1 shows the DigiTrace T2000 HTC with all of its components. Appendix A lists the specifications for all of these components. Flexible switch and wiring configurations allow the DigiTrace T2000 HTC to be used in most heat tracing applications. Please contact your nearest Pentair Thermal Management sales office to discuss your requirements. The following sections describe the primary function of each component CM 2000 CONTROL MODULE The CM 2000 control module is the original control module used in the DigiTrace T2000 system and has been replaced by the CM Firmware versions will range from versions V2.30 to V2.35. The CM 2000 control module is designed to provide all heat tracing control and monitoring functions for a single heating circuit. It easily inserts into any of the four types of card racks CM CONTROL MODULE The CM control module is an enhanced version of the original CM 2000 control module. Firmware versions will range from V3.14 and higher. The CM control module is designed to provide all heat tracing control and monitoring functions for a single heating circuit. It is compatible with any of the four types of card racks AC 2000 ALARM/COMMUNICATIONS INTERFACE CARD The AC 2000 is the original alarm/communications interface card designed for use with the DigiTrace T2000 system. As it is purely a hardware device and does not include a microprocessor, it contains no firmware. The AC 2000 is designed to provide a modem communications interface between the control modules and an external programming device (780/GCC-9000, 760/HHP-9000, or 761 PMP). One AC 2000 can act as the communications interface for up to 40 control modules. There are four LEDs on the front panel of the AC 2000 that indicate communication activity between the AC 2000 and any control module. There is also a single ALARM LED on the front panel to indicate the status of the AC 2000 s internal alarm relay. This dry contact alarm relay (0.5 A Max. 240 VAC Max.) is for remote alarm indication. It provides both a fail-safe normally open and a fail-safe normally closed set of contacts. These normal states are true if the AC 2000 is powered up and no alarms are present on any of the control modules (i.e.: the ALARM LED on the front panel of the AC 2000 is off). 6 / 81

7 The AC 2000 will only operate when inserted into the left-most slot of the card rack. However, the alarm relay connections are not available when using the CR or the CR 2000-CPS+ card racks. See Appendix B4 for details on wiring to an AC 2000 alarm/communications interface card AC ALARM/COMMUNICATIONS INTERFACE CARD The AC is an enhanced version of the original AC 2000 alarm/communications interface card. It includes a microprocessor that provides the user with many more features than the original AC Firmware versions may range from V1.00 and up. The AC is designed to provide communications interfacing (using isolated 2-wire RS-485, RS-232, or 10Base-T Ethernet) between the control modules and an external programming device that supports the Modbus protocol (see Section 1.3). Each communications port on the AC has its own RX and TX LEDs to indicate communication activity. The AC includes alarm and warning relay driver outputs to drive external relays connected to local annunciators. Each output has its own LED on the front panel, to indicate its status. The AC must only be inserted into the left-most slot of any of the four types of card racks. However, the alarm and warning relay driver outputs, and some of the communication ports are not available when using the CR 2000 or the CR 2000-CPS card racks. See Appendices B5 to B10 for details on wiring to an AC alarm/communications interface card CR 2000 CARD RACK The CR 2000 card rack was the original card rack designed for use with the DigiTrace T2000 system. It provided each control module its own isolated power supply connection. Two versions of this card rack have been manufactured. The first version did not support the ATC (Ambient Temperature Control) signal connection between the ten control modules, and the second (Rev A) version did support the ATC signal. The CR 2000 card rack is designed to provide mechanical protection and wiring terminals for one alarm/communications interface card and up to ten control modules. The card rack also provides wiring terminals allowing the interconnection of up to another three card racks. The following are the signal connections provided by the card rack for each of the ten control modules: Two RTD inputs One ground fault current transformer input One load current transformer input One output to control either an SSR or contactor Power supply input The following are the common signal connections provided by the card rack for each of the ten control modules: Communications connections with the alarm/communications interface card Control module alarm status signal ATC signal interconnection with each of the ten control modules The following are the signal connections provided by the CR 2000 card rack for the alarm/ communications interface card: A 2-wire communications connection (RS-485 or modem) for a remote programming device Power supply input One normally open dry contact relay output for a remote alarm indicator One normally closed dry contact relay output for a remote alarm indicator See Appendix B8 and Appendix B9 for wiring details for a CR 2000 card rack CR CARD RACK The CR card rack is similar to the original CR 2000 Rev A card rack (see Section 1.2.5), except that it has been modified to support the additional features of the AC alarm/ communications interface card. 7 / 81

8 1.3 EXTERNAL PROGRAMMING DEVICES The following connections are provided for the alarm/communications interface card: A 2-wire communications connection (RS-485 or modem) for a remote programming device Power supply input One warning relay driver output for driving an external relay One alarm relay driver output for driving an external relay A second 2-wire RS-485 communications connection for a local programming device An Ethernet connection See Appendix B10 for wiring details for a CR card rack CR 2000-CPS CARD RACK The CR 2000-CPS card rack is similar to the original CR 2000 card rack (see Section 1.2.5), except it is modified so that each of the ten control modules use a common power supply connection originating at the alarm/communications interface card in the left-most slot CR 2000-CPS+ CARD RACK The CR 2000-CPS+ card rack is similar to the CR card rack (see Section 1.2.6), except it is modified so that each of the ten control mod-ules use a common power supply connection originating at the alarm/communications interface card in the left-most slot CT 2000 CURRENT TRANSFORMER AND CONTRACTOR SWITCHING MODULE The CT 2000 current transformer and contactor switching module is used by a control module that implements a contactor as its output switch. The control module connects to the CT 2000 via the connections on the card rack (see Appendix B1). The CT 2000 is used to measure load and ground fault currents using internal current transformers as well as to switch an external contactor using an internal relay CT 2000-HAZ CURRENT TRANSFORMER MODULE A control module that implements an SSR as its output switch uses the CT 2000-HAZ current transformer module. The control module connects to the CT 2000-HAZ via the connections on the card rack (see Appendix B2 and Appendix B3). The CT 2000-HAZ is used to measure load and ground fault currents using internal current transformers. The external SSR is controlled directly by the control module via connections on the card rack BC 2000 BLANK COVER The BC 2000 blank cover is used to cover slots in the card rack that do not contain a control module or an alarm/communications interface card. The AC 2000+, CM 2000, and CM devices require an external programming device to view and modify their parameters and data. The type of device depends on the type of alarm/communications interface card being used by the DigiTrace T2000 HTC. The following sections give details on the programming devices that may be used with each type of alarm/ communications interface card AC 2000 PROGRAMMING DEVICES When using an AC 2000 alarm/communications interface card, only the following programming devices may be used to access the parameters and data of a DigiTrace T2000 HTC: 780/GCC-9000 Group Communications Controller 760/HHP-9000 Handheld Programmer 761 Panel Mount Programmer IMPORTANT: When using the 780/GCC-9000 Group Communications Controller, all of the programming devices mentioned in Section can be used upstream from the GCC. 8 / 81

9 1.4 CONTROL MODULE OVERVIEW AC PROGRAMMING DEVICES When using an AC alarm/communications interface card, only programming devices that support the Modbus protocol (Personal Computer, PLC, or DCS) may be used to access the parameters and data of a DigiTrace T2000 HTC. When using a personal computer, we recommend using the DigiTrace Supervisor Configuration and Monitoring software to manage your Digi-Trace control system. The software allows you to configure and monitor any DigiTrace controller installed in the field which includes an appropriate communications interface. The software also supports alarm monitoring, with the ability to acknowledge and clear alarms, and advanced features such as data logging, trending, recipes and batching. For portable solutions, use the DigiTrace PPD-IND or PPD-HAZ Portable Programming Devices. These Windows CE-based PDAs (Personal Digital Assistants) provide an intuitive, graphical user interface for configuration and troubleshooting. Access to all AC2000+ parameters is available, and interface cables are included to allow easy connection to your T2000 panel. For more information, refer to the Portable Programming Device (PPD) Software Installation and Operating Instructions document (H57402) DESCRIPTION The CM 2000 and the CM control modules, used in the DigiTrace T2000 HTC each control, monitor, and communicate alarms and data for a single heating circuit. As single point controllers, they offer a complete range of features as well as superior reliability. The ability to install the units in Class 1, Division 2 hazardous areas supports direct field installation if desired. The option to use either an external solid-state relay (SSR) or an external contactor to switch single phase or three wire, three phase loads up to 600 VAC, makes the CM 2000/CM control modules the most versatile products on the market FEATURES A detailed description of available features in the CM 2000 and the CM control modules may be found in Section 3 of this manual. Highlights of specific features are included in the following text. Digital Readout The actual temperature, the load current and the temperature setpoint are immediately accessible to plant operators and maintenance staff. The display units are field selectable in F or C. 40 to 149 F ( 40 to 65 C) Operation Extended temperature operation permits installation in all but the harshest environments. Single or Dual Temperature Sensor Inputs The ability to utilize one or two temperature sensor (TS) inputs, allows the selection of one of nine control modes and programming of all temperature parameters. High and Low Temperature Alarms High and low temperature alarms are offered for both temperature sensor inputs. High and Low Current Alarms The low current alarm is more than just a continuity level alarm. The control module offers full adjustment of both the high and the low alarm points over the entire current measurement range. Solid-state Relay (SSR) or Electro-mechanical Relay (EMR) Output The CM 2000/CM control modules are used with the CT 2000 current/switch module to monitor load and ground fault currents as well as drive a remote electro-mechanical relay (EMR) output switch. The CT 2000-HAZ current module is used to monitor load and ground fault currents when driving a solid-state relay (SSR). With the SSR option, the user may select a timeproportional control algorithm, a simple deadband control algorithm, or one of two ambient control algorithms. The EMR version always uses either the deadband control algorithm or the proportional ambient contactor control algorithm. Switching device failure alarms are supported for both types of output devices. 9 / 81

10 Ground Fault Alarm and Trip Ground Fault (GF) current levels are monitored and may be displayed in ma. The availability of the actual ground fault level gives the user the choice of both alarm and trip levels suitable for the particular installation. Overcurrent Protection A unique overcurrent protection algorithm greatly reduces the possibility of damage to the heating circuit or the SSR in the event of a temporary overload while allowing for initially high in-rush currents (SSR options only). Soft Starting Given the circuit breaker size, the control module will limit the energy let-through to help prevent nuisance breaker trips due to cable in-rush. This feature makes the control module particularly attractive for use with self-regulating cables (SSR options only). Minimum/Maximum Temperature Tracking The control module maintains the minimum and maximum temperature values it has measured since the last reset of these values. This is helpful in determining causes of temperature alarms. Latching/Non-latching Temperature Alarms User selectable non-latching temperature alarms allow the control module to automatically clear the alarm when the condition no longer exists. High and Low Voltage Alarms Operating at voltages less than design can cause serious loss of heater output. The alarming of preset voltage deviations ensures the availability of sufficient wattage output. Power-Limiting The control module will control the maximum output wattage if the full load power exceeds the specified Maximum Power Setpoint. This feature eliminates the need for low voltage transformers in many applications and can assist in standardization of heating cable types (SSR options only). Auto-cycling The control module will momentarily energize its heating circuit (for 10 seconds) at a programmable interval. Heating circuit alarms will be generated at the time of auto-cycle instead of when the heat is required. This feature eliminates the need for a preventative maintenance program as these tests are performed at regular intervals by the control module. Temperature Sensor Failure Alarm Both open and shorted sensors are detected and alarmed by the control module. Additionally, the control module may be configured to default to a remaining good sensor or to turn the output off. Random Start A startup delay between 0 and 9 seconds ensures that all control modules do not come on line at the same time following a power failure. Full Digital Communications All control modules can communicate alarm and analog data to a monitoring system via the alarm/communications interface card. With the availability of the heat trace data at the user s fingertips, historical trending of temperatures, power consumption, or other parameters are available for analysis and system optimization. CSA (C/US) & FM Approved The DigiTrace T2000 system is approved and certified for use in Class 1, Division 2, Groups A,B,C,D hazardous locations, making them ideal for direct installation in the field. This can save the expense of wiring back to a centrally located electrical distribution center. Compact Size Modules Innovative modular packaging allows for field addition of control modules as heating circuits are added. Individual heating circuits can easily be locked out or replaced without affecting other heating circuits. All heating circuits can be monitored simultaneously without scrolling. Universal Voltage Input The control module s wide voltage input range (90 to 240 VAC) gives the user maximum flexibility for installation and configuration as well as reducing the inventory requirements. 10 / 81

11 1.5 AC CARD OVERVIEW DESCRIPTION The AC alarm/communications interface card has similar functionality to the original AC 2000 Alarm/Communications interface card, but also combines the features of a Group Communications Controller (such as a Model 780/GCC-9000). The AC is designed to automatically poll all of the installed control modules for alarm data as well as maintain a database of their setpoints, setup parameters, alarm and analog data. Note that all control operations are performed by the CM 2000/CM control modules and not by the AC The user may configure setpoint or setup parameters for up to (40) CM 2000 and up to (256) CM control modules by using any of the AC ports. The AC communicates with the control modules through the backplane of the CR 2000/CR card rack(s). IMPORTANT: The AC belongs to a family of Group Communications Controller (GCC) devices. While specific to the DigiTrace T2000 series of products, the AC is nonetheless a Group Communications Controller (GCC). This nomenclature will be used through this user manual FEATURES A detailed description of available features supported by the AC alarm/communications interface card may be found in Section 7 of this manual. The following descriptions highlight specific features of the AC 2000+: Port Configuration All of the communications port configuration parameters of the AC may be reviewed or modified via the local front panel RS-232 port using a PC running the Communication Controller Configuration Utility program (see Section 1.5.3). Communication Ports All DigiTrace T2000 HTC parameters and data may be reviewed and modified through the following three communication ports of the AC 2000+: 1. Remote Port: This isolated RS-485 serial port allows up to (31) AC devices to be multidropped onto the same pair of RS-485 communication wires and then connected to a remote upstream programming device such as a host computer, PLC or DCS. 2. Local Port: This serial port may be configured to use either the front panel RS-232 interface or the 2-wire RS-485 interface on the back of a CR card rack. Select the RS-232 interface to connect with one Personal Computer, PLC or DCS in close proximity to the AC Select the RS-485 interface if a number of AC devices are to be multi-dropped onto the same pair of communications wires and connected to a local communications device. 3. Ethernet Port: This connection provides an industry-standard 10Base-T interface and supports a Modbus/TCP connection. This port is typically used when remote monitoring and configuration is required using an Ethernet Local Area Network (LAN). Relay Driver Outputs The AC has two fail-safe outputs to drive external 12Vdc relay coils. One is used for indicating Alarm conditions and the other for indicating Warning conditions. Monitoring The status of the AC 2000+, and all of the control modules are continuously monitored for proper operation and various alarm conditions. Control module information includes discrete setpoint, setup and alarm data, as well as analog values such as temperatures, currents, etc. Tags The AC and each control module may be assigned an identification tag eliminating confusing codes or cross-referencing. Tags may be up to 19 alpha-numeric characters in length. Load Shedding This is an advanced control mode, managed by the AC alarm/communications interface card. Load shedding overrides temperature control and forces the output of the selected control modules off until reset by the AC This mode is initiated by using a remote Modbus command from an external upstream programming device. See Sections to , 5.3, 7.4.2, 7.4.3, , and as well as Appendix E in this manual for details regarding the load 11 / 81

12 1.6 COMPONENT ORDERING GUIDE shedding features and related parameters ADDITIONAL DOCUMENTATION In addition to this manual, details of the Modbus protocol mapping for the AC may be found in the Group Communications Controller: Modbus Protocol Interface Linear Mapping and the Group Communications Controller: Modbus Protocol Interface Page Mapping documents. This information will be required to properly communicate with and operate the AC using a remote personal computer, process computer, or some other form of host computer system. The Communication Controller Configuration Utility, Installation and Operating Instructions document will provide information on how to set up various communication parameters required by the AC alarm/communications interface card using the Communication Controller Configuration Utility program SUPPORT Application assistance is available from Pentair Thermal Management for questions specific to the operation of the AC hardware and software or its use in conjunction with the CM 2000 and the CM control modules. The T2000 system consists of the following components: CR Card Rack (can accommodate one AC and p to 10 CM s) AC Alarm/Communications Interface CM Control Module CT 2000 CT Module Switching Device (Solid-state Relay or contactor) CR Card Rack AC Alarm/Communications Interface CM Control Module CT Module Switching Device (SSR or Contactor) 12 / 81

13 Figure 1.1 DigiTrace T2000 System Components The following tables summarize model codes for the DigiTrace T2000 series products. Note that the first table identifies the most recent products. These components should be specified for new designs. Current Product Model Codes Model Code Model Description Detailed Description CM DigiTrace T2000 Control Module with advanced feature set Plug-in control module, with firmware versions V3.14 and up, that provides all heat tracing control and monitoring functions. Plugs into all types of CR 2000 card racks and interfaces with all types of CT 2000 and AC 2000 modules. AC CR Alarm/Communications Inter-face Card with GCC functionality Isolated Power Card Rack supporting AC features Plug-in modules that provides RS-232, RS-485 or Ethernet interfacing between CM 2000/CM control modules and a PC or an external upstream programming device. Includes two relay output devices for remote alarm and warning indication. Panel mount rack provides mechanical protection and electrical connections for the CM 2000/CM control modules as well as the AC module. All control modules are individually powered. CR 2000-CPS+ CT 2000 CT 2000-HAZ Card Rack with Common Power Supply supporting AC features CT module for use with Electromechanical Contractors CT Module for use with Solidstate Relay Modules Approved For Hazardous Areas Panel mount rack provides mechanical protection and electrical connections for the CM 2000/CM control modules as well as the AC module. All control modules utilize a common power source. Current transformer and switching module. Load current conductors pass through to provide accurate load current and ground fault current measurements. Internal relay switches an external contactor. Interfaces with the CM 2000/CM control modules. Current transformer module. Load current conductors pass through this module to provide accurate load current and ground fault measurements. Internal circuitry drives an external solid-state relay. Interfaces with the CM 2000/CM control modules. 13 / 81

14 BC 2000 Blank Cover Blank cover plate to occupy empty or unused slots in all types of CR 2000 card racks. Legacy Product Model Codes Model Code Model Description Detailed Description CM 2000 Tracer 2000 Control Module Plug-in control module that provides all heat tracing control and monitoring functions. Plugs into all types of CR 2000 card racks and interfaces with CT 2000 and AC 2000 modules. Use a CM for new designs. AC 2000 CR 2000 CR 2000-CPS Alarm/Communications interface Card Isolated Power Card Rack Card Rack with Common Power Supply Plug-in module that provides a modem interface between CM 2000/CM control modules and an external 780 Series/GCC-9000, 760 Series/HHP-9000, or 761 Series programmer. Includes a relay for remote alarm indication. Panel mount rack provides a mechanical protection and electrical connections for the CM 2000/ CM control modules and the AC 2000 module. All control modules are individually powered. Use a CR for new designs. Panel mount rack provides a mechanical protection and electrical connections for the CM 2000/ CM control modules and the AC 2000 module. All control modules are individually powered. Use a CR 2000-CPS+ for new designs. 14 / 81

15 SECTION 2 INSTALLATION AND WIRING 2.1 INTRODUCTION 2.2 INITIAL INSPECTION 2.3 OPERATING ENVIRONMENT 2.4 INSTALLATION LOCATION 2.5 MOUNTING PROCEDURES WARNING: Electrical Hazard Ensure all personnel involved in installation, servicing, and programming are qualified and familiar with electrical equipment, their ratings and proper practices and codes. Multiple voltages and signal levels may be present during the installation, operation, and servicing of this product. Do not power the product until the safety provisions outlined in this section have been observed. This section includes information regarding the initial inspection, preparation for use, and wiring instructions for the components of the DigiTrace T2000 HTC. See Appendix B for wiring details. Inspect the shipping container for damage. If the shipping container or cushioning material is damaged, it should be kept until the contents of the shipment have been verified for completeness and the equipment has been checked mechanically and electrically. Procedures for configuring and operating the DigiTrace T2000 HTC are given in Sections 3 and 7. If the shipment is incomplete, mechanically damaged, defective in any way, or the DigiTrace T2000 HTC does not pass the electrical performance tests, notify the nearest Pentair Thermal Management representative. If the shipping container is damaged, or the cushioning material shows signs of stress, notify the carrier as well as your Pentair Thermal Management representative. Keep the shipping materials for the carrier s inspection. The standard CM 2000/CM control module using a Solid-state Relay (SSR) and a CT HAZ module, is suitable for Class 1, Division 2, Groups A, B, C and D hazardous areas. Hazardous areas are defined by Article 500 of the National Electrical Code and Section 18 of the Canadian Electrical Code. The standard CM 2000/CM control module using an Electro-mechanical contactor and a CT 2000 module is suitable for use in ordinary (non-hazardous) areas only. WARNING: Some wiring configurations will use more than one power source and all must be de-energized prior to performing any maintenance on a control module or its heating circuit. The operating environment should be within the limitations specified for the DigiTrace T2000 HTC components as outlined in Appendix A. The wide ambient operating temperature range of the DigiTrace T2000 HTC permits installation in most any convenient location. Considerations should include expected atmospheric conditions, accessibility for maintenance and testing, the location of existing conduits, and hazardous area rating. Ambient temperature conditions may affect load current ratings. WARNING: Fire and Explosion Hazard Be sure the product is approved for the intended location as defined by Article 500 of the National Electrical Code and/or Part I, Section 18 of the Canadian Electrical Code CARD RACK REMOVAL AND INSTALLATION WARNING: Shock Hazard Turn off all power to the card rack and individual control modules during installation or removal to avoid the risk of injury to personnel and damage to the DigiTrace T2000 HTC. 15 / 81

16 WARNING: Electrical Hazard Always verify all wiring connections before applying power to the card rack or any heating circuit. To avoid injury or equipment damage, do not install or remove wiring while power is on. Both types of CR 2000 and CR card racks are designed to be mounted to a swing out door of a panel using four card rack mounting brackets (see Appendix D for panel cutout and dimensions). Remove all wires connected to the terminal blocks on the back of the card rack by inserting a small bladed screw driver in the terminal block slot and pulling the wires out of the terminal block. Pay particular attention to the location of each wire, as all wires must be terminated properly upon replacement for proper operation. Incorrect terminations may damage a control module or the alarm/communications interface card. To remove the card rack from the panel, loosen the mounting screw on each of the four mounting brackets located on both the top and bottom sides of the card rack. Once loose, the mounting bracket may be removed from the card rack by sliding it forward and lifting vertically from the card rack. Install in the reverse order CONTROL MODULE REMOVAL AND INSTALLATION WARNING: Shock Hazard Always ensure that all power to the individual control modules is turned off during installation or removal to avoid the risk of injury to personnel and damage to the control modules. WARNING: Hazardous Area Explosion Hazard Do not install or remove the control module while the unit is powered. To remove a control module from any of the ten right-most slots of the card rack, loosen the screw on the top front edge of the control module faceplate. However, do not remove it! Once the screw has been loosened approximately 1/4, grasp the screw and pull firmly straight out, away from the card rack. If the screw is still engaged, slowly loosen it by hand continuing to pull away from the card rack. When the mounting screw is free of the card rack, slide the control module out of the card rack by grasping the faceplate. Do not handle the control module by the PC board. Store immediately in the anti-static bag provided. Install in the reverse order ALARM/COMMUNICATION INTERFACE CARD REMOVAL AND INSTALLATION WARNING: Always ensure that all power to the alarm/communications interface card is turned off during installation or removal to avoid the risk of injury to personnel and damage to the card. WARNING: Hazardous Area Explosion Hazard Do not install or remove the alarm/communications interface card while the unit is powered. To remove an Alarm/communications Interface card from the left-most slot of the card rack, loosen the screw on the top front edge of the card s faceplate. However, do not remove it! Once the screw has been loosened approximately 1/4, grasp the screw and pull firmly straight out, away from the card rack. If the screw is still engaged, slowly loosen it by hand continuing to pull away from the card rack. When the mounting screw is free of the card rack, slide the interface card out of the card rack by grasping the faceplate. Do not handle the interface card by the PC board. Store immediately in the anti-static bag provided. Install in the reverse order. IMPORTANT: When using an AC 2000 with a CR or a CR 2000-CPS+ card rack, the dry contact alarm relay connections are not available. 16 / 81

17 When using an AC with a CR 2000 or a CR 2000-CPS card rack, the alarm and warning relay driver outputs, the Ethernet communication port, and the Local RS-485 communication port are not available CT MODULE REMOVAL AND INSTALLATION WARNING: Always ensure that all power to the individual heating circuit is turned off during installation or removal to avoid the risk of injury to personnel and damage to the CT module. WARNING: Hazardous Area Explosion Hazard Do not install or remove the CT module while the unit is powered. To remove a CT module, first remove the wires that pass through the CT module from the contactor, SSR, or the field wiring terminals and carefully pull the wires through the CT module housing. Next remove all of the wires from the CT module terminal block by inserting a small bladed screw driver in the terminal block slot and pulling the wire out of the terminal block. Remove the two mounting screws and remove the CT module. Install in the reverse order. 2.6 WIRING Wire the card rack as indicated by the wiring diagrams supplied. See Appendix B for a complete set of wiring diagrams. All terminals are labeled with terminal numbers and the corresponding legend is printed on the wiring label beside the terminal block. Do not to use wire sizes that exceed the marked terminal ratings and avoid terminating two wires on the same terminal. Use of the incorrect screwdriver size may damage the terminals. Use the terminal block behind the right-most slot, to connect the following three termination resistors: 3300 Ω resistor across the terminals labeled SIG + and SIG 120 Ω resistor across the terminals labeled TX/RX + and TX/RX 120 Ω resistor across the terminals labeled RTS/DCD + and RTS/DCD 120 Ω resistor across the terminals labeled REMOTE + and REMOTE (AC only) 120 Ω resistor across the terminals labeled LOCAL + and LOCAL (AC only) Use twisted, three-conductor shielded cable for extending RTD leads. Wire size should ensure that the maximum lead resistance specified for the CM 2000/CM is not exceeded. Communications wiring should be two conductor twisted shielded cable. Shields on both RTD and communications wiring should be grounded at one end only. Communications cable shield should only be grounded at the alarm/communications interface card terminal provided. RTD cable shields should be grounded at the control module terminal provided. If the card racks are installed in either a metallic or non-metallic enclosure, follow the enclosure manufacturer s recommendations for proper grounding. Do not rely on conduit connections to provide a suitable ground. A ground terminal is provided on each card rack for connection of a system ground lead. Proper system grounding is required for safe and correct operation of the DigiTrace T2000 HTC protection features. Refer to Article 501-4(b) of the National Electrical Code for grounding in hazardous areas, if appropriate ISOLATED POWER SUPPLY CARD RACK (CR 2000 & CR 2000+) Conductors used to power the individual control modules and the alarm/communication interface card, CT module signals, sensor inputs, alarm circuits and controller communications all terminate on the back of the card rack. The standard card rack assembly has an individual power source for each control module, therefore more than one power source will be present on the card rack terminal blocks (see Appendix B) COMMON POWER SUPPLY CARD RACK (CR 2000-CPS & CR 2000-CPS+) Conductors used to power the individual control modules and the alarm/communication interface 17 / 81

18 card, CT module signals, sensor inputs, alarm circuits and controller communications all terminate on the back of the card rack. The CPS card rack assembly has a common power source for all control modules. Power supply connections are made on the left-most slot (see Appendix B for wiring details) CT MODULE (CT 2000 & CT 2000-HAZ) Electrical conductors for the heat tracing load pass through the CT module housing and do not terminate at the CT module. CT signal wires terminate on the CT module terminal block located on the top of the CT module. For the CT 2000 module, the contactor coil control wires terminate on the CT module terminal block located on the top of the CT module. Switch control and CT signals must be terminated as shown in the wiring diagrams in Appendices B-1 to B-3 WARNING: Be certain that power has been removed from the heating circuit and control module prior to disconnecting the switch control or CT signal leads INTERCONNECTING MULTIPLE CARD RACKS When using an AC 2000 alarm/communication interface card, up to 4 card racks (containing a maximum of (40) CM 2000 or CM control modules) may be daisy-chained together to one AC When using an AC alarm/communication interface card, up to (26) card racks (containing a maximum of (256) CM control modules) may be daisy-chained together to one AC IMPORTANT: The AC may be used with CM 2000 modules, however a maximum of 4 card racks (40 CM 2000s) may be daisy-chained together. When sharing a single alarm/communications interface card among multiple card racks, it is always inserted in the left-most slot of the first card rack. The left-most slots of the remaining card racks are left empty. Each card rack has two terminal blocks on the back at either side, which allows for convenient daisy-chaining of card racks. When daisy-chaining card racks, use twisted multi-conductor shielded cable with the shield terminated on the terminal block provided at the previous card rack. The termination resistors are only required on the last card rack in the chain. See Appendices B4 and B5 for wiring details. 2.7 INITIAL POWER-UP WARNING: Before applying power to the DigiTrace T2000 HTC: Close the panel door or stand clear of the DigiTrace T2000 HTC. Although the control modules incorporate overcurrent protection, a destructive switch failure can result from a short circuited output. To avoid the possibility of any injury, no one should be directly in front of the switches when they are initially powered up. Ensure that applying power to any heating circuit will not damage it if power limiting or the setpoint temperature have not been set correctly. If there is any doubt, the load should be disconnected until the control module has been suitably programmed for correct and safe operation. To minimize the risk of damage to the control module and its components due to a cable fault, the integrity of the heating cable should be verified. This can be accomplished by performing a high voltage insulation test using a Megger following the heating cable manufacturer s instructions. Ensure that the heating cable is not shorted by measuring the resistance using an ohmmeter. These tests must be performed with the heating cable completely disconnected. Once the heating cable has been checked, it may be reconnected and power applied. 18 / 81

19 SECTION 3 CONTROL MODULE PROGRAMMING AND CONFIGURATION 3.1 INTRODUCTION AND INITIAL POWER-UP 3.2 FRONT PANEL FEATURES Section 3 provides complete operating and programming details for the CM 2000 and the CM control modules. These details consist of initial power-up information, front panel features, and function descriptions including: purpose, valid range settings, the procedure for use, and some operational tips and suggestions RANDOM START-UP DELAY All CM 2000 and CM control modules incorporate a random start-up delay feature, ensuring that all units do not power on their load the same time. When power is first applied to a control module, it will hold its output off for a random time (0 to 9 seconds), equal to the last digit of the address displayed on the front panel of the control module. Once this start-up delay has timed out, the control module will begin normal operation POWER-UP OUTPUT ENABLING When power is applied to a CM 2000 control module it will always turn its output on for approx. 6 seconds if the load shedding mode is disabled. When power is applied to a CM control module it will only turn its output on for approx. 10 seconds if the auto-cycling feature has been enabled and if the control module is not in load shedding mode. By momentarily turning the control module s output on at power-up, the integrity of the heating circuit is tested and any faults will be detected immediately AUTO COMMUNICATIONS DATA RATE SELECTION (CM ONLY) All CM control modules will support either low or high speed data communications to allow their use in either existing (low speed) systems or new (high speed) installations. The CM will automatically set its communications data rate to either 300 or 9600 baud. This selection is based on the data rate of the first l communication detected by the CM after it is reset. All control modules sharing a common communication bus must communicate at the same data rate. To disable this feature, install the E6 jumper on the CM module. By doing this, the CM will only communicate at 300 baud. Front panel features of the control module are described in Figure 3-1. This figure contains a detailed description of the indicators and label information. The remainder of this section describes in detail the front panel display and status LEDs CONTROL MODULE FRONT PANEL DISPLAY The three-character (seven segment plus decimal LED) display is found near the top of the front panel of the CM 2000/CM control modules. It is used to indicate certain quantitative values to the operator. This display shows measured temperature and setpoint values in F or C as well as actual load current in amperes. When the three-character display is displaying a temperature value, either the F LED or C LED on right hand side of the display will be illuminated depending on temperature units selected by the operator. Also, when displaying temperature values in F, the decimal point for the right-most character will also be illuminated DISPLAY OPERATION All CM 2000 and CM control modules have a random start-up delay associated with them as described in Section When power is first applied to a control module, it will display the startup delay (in seconds) and count down to zero. Immediately after this count down has completed, the control module briefly (approximately 1/10 of a second in duration) displays the version number of its operational program (firmware). This allows the user to refer to specific Sections of the documentation as they relate to functions for a particular version of the control module. The control module then turns on all LEDs (except TRANSMIT and RECEIVE LEDs for the CM 2000) and sequences through a test pattern so that the operator can verify that all LEDs and display segments are functioning. 19 / 81

20 The control module will then begin to display the following three parameters in sequence: Actual measured temperature from the temperature sensor(s), Heat trace load current in amperes, and The CONTROL SETPOINT temperature. As these three values are displayed (each for approximately 2.5 seconds in duration), a corresponding LED immediately below the display area illuminates to indicate which parameter is being shown. Under certain conditions, the control module will display several messages on the three-character display in place of one of these three parameters (see Section 3.3) TEMP STATUS LED The TEMP status LED is located below the left-most character of the control module s front panel display. When illuminated, this LED indicates that the present value being shown on the display is the actual temperature of the designated control temperature sensor (as determined by the TS CONTROL MODE setting) CURRENT STATUS LED The CURRENT status LED is located below the middle character of the control module s front panel display. When illuminated, this LED indicates that the present value being shown on the display is the actual heat trace load current in amperes. If this LED is flashing, then it indicates that the control module has measured a ground fault current in excess of the GF TRIP CURRENT or has encountered a severe overcurrent situation and has tripped the output off SETPT STATUS LED The SETPT status LED is located below the right-most character of the control module s front panel display. When illuminated, this LED indicates that the present value being shown on the display is the present value of the CONTROL SETPOINT temperature setting OUTPUT STATUS LED The OUTPUT status LED is located below the SETPT status LED on the right side of the control module s front panel display. When illuminated steadily, this LED indicates that the output switch (contactor or SSR) is on and is allowing current to flow into the heating circuit. If this LED is flashing, it indicates that the control module is pulsing its output on and off to maintain the CONTROL SETPOINT temperature and/or control the average amount of current/power that the heating load uses (proportional control mode, SSR option only) ALARM STATUS LED The ALARM status LED is located below the OUTPUT status LED on the right side of the control module s front panel display. The color of this LED is amber for the CM 2000+, and red for the CM If the control module detects any alarm condition, this LED will flash at a rate of once per second TRANSMIT STATUS LED The TRANSMIT status LED is located below the ALARM status LED on the right side of the control module s front panel display. This LED will flash whenever the control module sends information over its communication port to either the AC 2000 or the AC alarm/communications interface card RECEIVE STATUS LED The RECEIVE status LED is located below the TRANSMIT status LED on the right side of the control module s front panel display. This LED will flash whenever the control module receives information over its communication port from either the AC 2000 or the AC alarm/ communications interface card. 20 / 81

21 3.3 DISPLAYED ALARM INDICATORS Under certain conditions, the three-character display is used to indicate critical alarms or unique operating conditions. For most of these indications, the control module output is turned off, not allowing any current to flow to the heating circuit. These alarm conditions may indicate that the DigiTrace T2000 HTC or the heating load require immediate attention. This section describes in detail the various types of alarm indications that the control module may display TEMPERATURE SENSOR FAILURE When the temperature sensor(s), designated as the control temperature sensor(s), fail to operate properly, the output will be switched off and the display will appear as follows: Flashing Always Displayed OVERCURRENT TRIP When the control module encounters a severe overcurrent situation, the output will be switched off and the display will appear as follows: Flashing Displayed In Place of Current Load GROUND FAULT CURRENT TRIP When the control module measures a ground fault current in excess of the GF TRIP CURRENT the output will be switched off and the display will appear as follows: Flashing Displayed in Place of Load Current TEMPERATURE DISPLAY RANGE OVERFLOW When the control module has to display a measured control temperature or a CONTROL SETPOINT temperature greater than the display maximum of 999, the display will appear as follows: Flashing Displayed In Place of Control Temperature or Control Setpoint Temperature IMPORTANT: In order to view the actual temperature value, the operator must use an external upstream programming device. 21 / 81

22 3.3.5 PRIORITY ACTIVE (LOAD SHEDDING/FAIL SAFE) When the control module is put into priority mode (load shedding or fail safe) the output will be switched off (unless fail safe is active) and the display will appear as follows as long as the priority mode persists: Flashing Displayed In Place of Load Current IMPORTANT: See Section 5.3 for a detailed explanation of the operation of the load shedding and fail safe modes FREEZE PROTECTION MASTER (V2.35 AND UP) When a control module (with firmware version V2.35 or higher), is configured as a Freeze Protection Master or as an Ambient Temperature Control (ATC) Master, immediately after the CONTROL SETPOINT temperature is displayed, the display will appear as follows: Displayed After Control Setpoint Temperature ATC SLAVE (V2.35 AND UP) When a control module (with firmware version V2.35 or higher) is configured as an ATC SLAVE, the display will appear as follows: Displayed In Place of Control Setpoint Temperature ATC FAILURE (V2.35 AND UP) When a control module (with firmware version V2.35 or higher) is configured as an ATC SLAVE and the ATC signal from the ATC MASTER is absent, then the display will appear as follows: Flashing Displayed in Place of Control Setpoint Temperature NO TS CONNECTED (V2.35 AND UP) When a control module (with firmware version V2.35 or higher) is configured as an ATC SLAVE, the TS 1 FAILURE ALARM is disabled, and there is no RTD connected to the TS 1 input, then the display will appear as follows: 22 / 81

23 Displayed in Place of Control Temperature TS 1 FAILURE (V2.35 AND UP) When a control module (with firmware version V2.35 or higher) is configured as an ATC SLAVE, the TS 1 FAILURE ALARM is enabled, and there is no RTD connected to the TS 1 input (or the RTD is malfunctioning), then the display will appear as follows: Flashing Displayed in Place of Control Temperature EEROM DATA FAILURE If the control module s non-volatile EEROM memory malfunctions and loses a portion or all of its contents, the control module will reload the factory default values for the lost portion of memory and the display will appear as follows: Flashing Always Displayed CONTROL MODULE UNCALIBRATED If the control module loses its calibration information, the display will appear as follows: Flashing Always Displayed If Control TS Failure Else Displayed In Place of Control Temperature FACTORY PARAMETERS UNLOCKED (CM ONLY) If the factory parameters of a CM control module become unlocked then the display will appear as follows: Flashing Always Displayed 23 / 81

24 3.4 POINT SETUP PARAMETERS An external programming device as mentioned in Section 1.3 of this manual must be used to perform the proper setup of the CM 2000/CM control module and adjust all of its setpoints. For instructions on the operation of these external programming devices, refer to their corresponding operating manuals. The sections that follow explain the various setup parameters of the CM 2000/CM control module and how they may be accessed. The first line of each section identifies the parameter to be described. The text then proceeds with an explanation of the Purpose of the parameter, the Range over which it may be set, the Procedure for setting or enabling the parameter, and finally any Notes or Examples that pertain to that particular parameter ALPHA-NUMERIC TAG ASSIGNMENT Purpose: A 19 character alpha-numeric TAG may be assigned to a control module to allow it to be easily associated with a pipe, vessel, process, heating circuit, drawing name or number. Setting: Any combination of 19 characters from A-Z, 0-9, /, -,., (, ) or # may be used. Procedure: Use an external programming device to enter the desired text TEMPERATURE DISPLAY UNITS Purpose: This allows selection of the units to be used to display temperatures on the front panel of the control module. Both the measured control temperature and the CONTROL SETPOINT temperature will be displayed in the selected units. Degrees F or C operation is indicated by the illumination of the corresponding temperature units LED on the right hand side of the display (See Figure 3-1). Also, if F is selected, then the decimal of the right-most character will be illuminated along with the temperature value. Setting: DEGREES F or DEGREES C Procedure: Adjust the setting to the desired temperature units ( F or C). IMPORTANT: This setting will not affect the temperature units displayed by any external upstream programming device except the Handheld Programmer (Model 760/HHP-9000), or the Panel Mount Programmer (Model 761). To minimize possible confusion, it is recommended that the temperature units be set to use the same units on all the control modules and all external upstream programming devices CONTROL SETPOINT TEMPERATURE Purpose: If a control module is not configured as an ATC SLAVE, the CONTROL SETPOINT temperature is the value at which the control module will maintain the heating circuit temperature. The CONTROL SETPOINT temperature is compared to the actual temperature measured by the control temperature sensor (TS). A decision is then made to turn on or turn off the output to control power to the heating circuit. Range: 76 to 1058 F ( 60 to 570 C) Procedure: Adjust the CONTROL SETPOINT temperature value to the desired maintain temperature. The control module will switch the output on and off to maintain this temperature. IMPORTANT: See Section 5.2 of this manual for an explanation of the Proportional, Proportional Ambient SSR, Proportional Ambient Contactor and Deadband Control algorithms SWITCH CONTROL MODE Purpose: If a control module is not configured as an ATC SLAVE, this feature allows the selection of the type of algorithm to be used by the control module to maintain the CONTROL SETPOINT temperature. There are four different control algorithms available in the CM control module and two in the CM 2000 control module: proportional, proportional ambient SSR (CM only), proportional ambient contactor (CM only) and deadband. See Section 5.2 of this manual for a complete explanation of these controlling techniques as they are implemented in the control module. 24 / 81

25 Setting: PROPORTIONAL, PROPORTIONAL AMBIENT SSR (CM 2000+), PROPORTIONAL AMBIENT CONTACTOR (CM 2000+) or DEADBAND Procedure: Select the desired control technique. Note that deadband control and proportional ambient contactor should be selected when using contactors or when precise control and advanced current handling functions are not required. IMPORTANT: If deadband control is selected, a DEADBAND setting will be available in the control module configuration menu, otherwise, a PROPORTIONAL BAND setting will be available. MAXIMUM POWER, SWITCH CURRENT RATING and CIRCUIT BREAKER CURRENT RATING settings are not available when the control module is set to operate in either contactor mode. If proportional ambient contactor is selected, the CYCLE TIME setting will also be available DEADBAND SETTING (Deadband control mode only). Purpose: If a control module is not configured as an ATC SLAVE and is equipped with a contactor, to control a heating circuit, it is necessary to use deadband rather than proportional control. This is done to prevent the contactor from switching on and off rapidly and wearing out prematurely. This deadband uses on/off control, where the decision to turn the output off or on is based upon the difference between the measured control temperature and the desired CONTROL SETPOINT temperature. Range: 5 to 90 F (3 to 50 C) for CM to 90 F (1 to 50 C) for CM Procedure: Adjust the DEADBAND setting to achieve the desired level of temperature control. When the control temperature is above the setpoint + deadband value, the control module will turn off its output. If the control temperature drops below the setpoint, the output will be turned on. Note that the smaller the DEADBAND setting, the more often the contactor will cycle on and off, decreasing its operational life. IMPORTANT: See Section 5.2 of this manual for an explanation of Deadband Control. Note that the MAXIMUM POWER, SWITCH CURRENT RATING, and CIRCUIT BREAKER CURRENT RATING settings are not available when the control module is set to deadband control mode (typically when switching a contactor). The DEADBAND must be set when a control module is configured as an ATC MASTER and its SWITCH CONTROL MODE is set to PROPORTIONAL. This is because the ATC output signal from the Master control module will use the deadband control mode to control any Slave control modules PROPORTIONAL BAND SETTING (CM ONLY) (For use with the three proportional control modes only). Purpose: If a control module is not configured as an ATC SLAVE and uses an SSR to control the heating circuit, then proportional or proportional ambient SSR modes are normally used, allowing for more precise temperature control. When using contactors, and control decisions are to be made based on the ambient temperature, the proportional ambient contactor mode is used. This programmable proportional band acts to vary the on to off time of the output based on the difference between the measured control temperature and the desired CONTROL SETPOINT temperature. Range: 2 to 90 F (1 to 50 C) 2 to 630 F (1 to 350 C) for versions V3.19+ only Procedure: Adjust the PROPORTIONAL BAND setting to achieve the desired temperature control. IMPORTANT: See Section 5.2 of this manual for an explanation of how the three proportional modes use the PROPORTIONAL BAND setting. For the CM 2000 control modules (V2.35 and lower), the PROPORTIONAL BAND is fixed at 2 F (1 C), and centered around the CONTROL SETPOINT temperature. 25 / 81

26 When using series-type, constant wattage, or self-regulating tracers in an ambient temperature control application, significant energy savings may be realized versus traditional ambient control algorithms. Heat Tracing design is normally done assuming worst-case conditions, where 100% of the design output power (less an appropriate safety factor) is required to maintain the desired minimum temperature. When the ambient temperature is above the design minimum, but some heat is still required, adjusting the PROPORTIONAL BAND width accordingly will allow only the amount of power required by the application to be consumed, while maintaining the minimum required temperature. Example: A water line must be protected from freezing when the ambient temperature falls below 50 F (10 C). Either the proportional ambient SSR or proportional ambient contactor mode is selected as the control method (depending on the type of switch being used). The heater and insulation combination are chosen to impart enough heat to the line to keep it from freezing at a worst-case ambient temperature of 40 F ( 40 C). At 50 F (10 C), the heater should be completely off, since no heat is required at this temperature to guarantee that the water will not freeze. It follows that the amount of heat required by the water line decreases as the ambient temperature increases from 40 F ( 40 C) to 50 F (10 C) (theoretically, at 5 F ( 15 C) the heater output should be approximately 50%). Setting the CONTROL SETPOINT temperature to 50 F (10 C), and the PROPORTIONAL BAND to 122 F (50 C), will force the control module s output to be 100% on at 40 F ( 40 C), 50% on at 5 F ( 15 C), and off at 50 F (10 C) CYCLE TIME SETTING (CM ONLY) (For proportional ambient contactor control mode only when not configured as an ATC SLAVE). Purpose: This parameter determines the minimum amount of time it will take for a complete contactor on-off-on cycle when using proportional ambient contactor control. Range: 10 to 255 Minutes Procedure: Adjust the CYCLE TIME setting to yield the desired contactor on+off time for a particular duty cycle. For instance, if the contactor should remain on for 5 minutes with a 50% duty cycle, then the CYCLE TIME should be 10 minutes. A new duty cycle (based on measured control temperature, PROPORTIONAL BAND and CONTROL SETPOINT) is calculated every time the contactor is required to change state. IMPORTANT: If the calculated duty cycle is 0% or 100%, then the contactor will not change state and the duty cycle will not be calculated again for a time period = CYCLE TIME/30. The minimum cycle time setting is 10 minutes, and the control module s minimum output duty cycle is 3%. This results in a minimum contactor on time of 18 seconds SWITCH CURRENT RATING SETTING (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the SWITCH CURRENT RATING setting defines the current rating of the output switch. This parameter is used by the control module soft start feature to limit the maximum average current that will be allowed to flow to the load during overcurrent conditions. This will minimize the potential for SSR damage. Range: 0.3 to 50.0 A for CM to 60.0 A for CM Procedure: Adjust the SWITCH CURRENT RATING setting to match the current rating of the output device (i.e A) CIRCUIT BREAKER CURRENT RATING SETTING (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the CIRCUIT BREAKER CURRENT RATING setting helps prevent in-rush induced nuisance tripping of the circuit breaker immediately upstream of the control module. The control module evaluates the square of the current related to time (I2t) and adjusts the output duty cycle accordingly, limiting the amount of current to an acceptable level. Range: 0.3 to 60.0 A for CM to 120% of SWITCH CURRENT RATING for CM / 81

27 Procedure: Adjust the CIRCUIT BREAKER CURRENT RATING setting to match the heating circuit breaker size (i.e A). IMPORTANT: This feature SHOULD NOT be used to reduce the size of a circuit breaker or increase the maximum heating cable length. It can be quite effective in preventing nuisance trips due to incorrect design or factors outside those considered by the design MAXIMUM POWER SETTING (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, this user selectable level limits the maximum amount of power applied to a heating circuit. This is an average power calculated by the control module using the average current and applied voltage. The control module switches the output on and off rapidly to limit the average current to an appropriate level. The MAXIMUM POWER level may be adjusted to eliminate step-down transformers, lower the effective output wattage of a cable, or implement energy management of the heating circuit. Range: 3 to 30,000 watts for CM to 60,000 watts for CM (Range depends on VOLTAGE TURNS RATIO) Procedure: Adjust the MAXIMUM POWER level to the desired value. Use the TEST tracing function (see Section 4.2.8) to observe the power limiting operation. IMPORTANT: This function may be set within reasonable limits for the particular tracer being powered. The effective resolution of the setting is limited to 1/30th of the calculated full on power. Do not set the MAXIMUM POWER level below the full output level for applications that do not require power limiting TEMPERATURE SENSOR CONTROL MODE Purpose: The TS CONTROL MODE allows the selection of one of nine possible temperature control modes used by the control module. The different modes allow redundant fail-safe temperature sensing, averaging, or minimum maintain temperature control. Setting: Select one of the following nine possible TS CONTROL MODES: CONTROL USING TS 1, FAIL OFF CONTROL USING TS 1, FAIL TO TS 2 CONTROL USING TS 2, FAIL OFF CONTROL USING TS 2, FAIL TO TS 1 CONTROL ON AVERAGE, FAIL OFF CONTROL ON AVERAGE, FAIL TO GOOD CONTROL ON LOWEST, FAIL OFF CONTROL ON LOWEST, FAIL TO GOOD The ninth TS CONTROL MODE below is only available in control modules with firmware versions V2.35 or higher, and if the control module is not configured as an ATC MASTER: CONTROL AS AN ATC SLAVE Where FAIL OFF = Control module s output switch will get turned off if the control TS fails. Example: With a TS CONTROL MODE set as CONTROL ON AVERAGE, FAIL TO GOOD, the control module will measure both sensors (TS 1 and TS 2), average the two temperature values, display the results and cycle the heater on or off to maintain the CONTROL SETPOINT temperature. This is the primary control mode. If either sensor should fail, the control module will transfer control to the remaining good sensor and generate the appropriate TS 1 or TS 2 FAILURE ALARM (assuming the alarm is enabled). The temperature will now be maintained based on this measured value. If the remaining good sensor fails, the control module will turn the heater off. The three-character display will always flash tsf and the appropriate TS 1 or TS 2 FAILURE ALARM will be also be generated as well as the Control TS FailURE ALARM (assuming these alarms are enabled). Procedure: Select the temperature sensor control mode that best suits the application. 27 / 81

28 IMPORTANT: Ensure that TS FAILURE ALARMS are enabled. See Sections 3.4, 3.5.7, and for a complete explanation of RTD failure detection in the control module. If the selected TS CONTROL MODE is ATC SLAVE then the CONTROL TS FAILURE ALARM is non-latching and the load shedding fail safe mode is always disabled. Also, the three-character display will display Atc in place of the CONTROL SETPOINT temperature. If there is no ATC signal present, then three-character display will flash AtF in place of the CONTROL SETPOINT temperature and the output will be off ATC MASTER MODE (V2.35 AND UP) Purpose: If a control module is not configured as an ATC SLAVE, it can be configured as an ATC MASTER. In this mode a control module will control its own output as well as the outputs of any control module which is configured as an ATC SLAVE. When a control module is configured as an ATC MASTER the three-character display will display FrP immediately after the CONTROL SETPOINT temperature is displayed. Setting: YES or NO Procedure: If a control module is to be an ATC MASTER then select YES, otherwise select NO. IMPORTANT: It is possible to have more than one ATC MASTER control module controlling a group of ATC SLAVE control modules. The ATC SLAVES will have their outputs on if one or more ATC MASTER is instructing them to have their outputs on. Otherwise the ATC SLAVES will have their outputs off. If an ATC MASTER controls its own output using either the DEADBAND or PROPORTIONAL control modes then it will control its ATC output using the DEADBAND control mode. If an ATC MASTER controls its own output using either the PROPORTIONAL AMBIENT SSR or PROPOR- TIONAL AMBIENT CONTACTOR control modes then it will control its ATC output using the PROPORTIONAL AMBIENT CONTACTOR control mode. For control modules with firmware versions V3.18 and up, the ATC output signal of an ATC MASTER is not affected by load shedding or fail safe modes, auto-cycling, EEROM data failure, GFI trip, or overcurrent trip. For control modules with firmware versions V3.18 and up, if an ATC MASTER controls its output using either the PROPORTIONAL AMBIENT SSR or PROPORTIONAL AMBIENT CONTACTOR control modes, and a control temperature failure occurs, then the ATC output signal will remain unchanged until the current duty cycle expires VOLTAGE TURNS RATIO ADJUSTMENT Purpose: The VOLTAGE TURNS RATIO adjusts voltage readings for applications where a control module is switching a load through a step-up or step-down transformer, or is being powered from a source with a different voltage level than the trace voltage. Range: 0.10 to 9.90 (TO 1) Procedure: Adjust the VOLTAGE TURNS RATIO to equal the ratio of the heating circuit voltage to the control module input voltage. Compare the voltage indicated by the control module to the actual measured heating circuit voltage after setting the turns ratio and adjust until the two readings are as close as possible. Example: Heating Circuit Voltage: 480 Volts Control Module Input Voltage: 120 Volts VOLTAGE TURNS RATIO Setting: 4.00 To 1 IMPORTANT: When the VOLTAGE TURNS RATIO has been set appropriately, the control module will calculate the heating circuit power using the adjusted current and voltage readings. Voltage alarms also use the adjusted voltage reading. 28 / 81

29 CURRENT TURNS RATIO ADJUSTMENT (For deadband and proportional ambient contactor control modes only). Purpose: The CURRENT TURNS RATIO adjusts current readings for applications where a control module is monitoring a load through an external step-up or step-down current transformer. Range: 0.10 to (TO 1) Procedure: Adjust the CURRENT TURNS RATIO to equal the ratio of the primary to secondary windings of the external current transformer. Compare the current indicated by the control module to the actual measured heating circuit current after setting of the CURRENT TURNS RATIO and adjust until the two readings are as close as possible. IMPORTANT: When the CURRENT TURNS RATIO has been set appropriately, the control module will calculate the heating circuit power using the adjusted current and voltage readings. Current alarms also use the adjusted current reading AUTO-CYCLE ENABLING Purpose: The auto-cycle function momentarily (approximately 10 seconds) applies power to the heating circuit at the selected interval. It is used to test the integrity of the heating circuit. Alarms present at the time of auto-cycle then become latched and remain active after the completion of the auto-cycle function. Auto-cycling effectively eliminates the need for preventive maintenance by automatically verifying the integrity of the heating circuit. Setting: ENABLE or DISABLE Procedure: Enable or disable the auto-cycling feature as desired. AUTO-CYCLE INTERVAL and AUTO-CYCLE UNITS can only be set if AUTOCYCLE is enabled. IMPORTANT: Auto-cycling should always be enabled for normal operation. This feature should only be disabled if the control module s heating circuit is being monitored or exercised by some other device or means. Although this function defeats temperature control and forces output on, the control module will continue to adjust the output for protection purposes or power limiting (SSR option only). Auto-cycling is inhibited if the control module is in load shedding mode (see Section 5.3). The CM 2000 control module will always auto-cycle for 6 seconds when power is initially applied to the control module and load shedding mode is disabled. However, the CM control module will only auto-cycle for 10 seconds when power is initially applied to the control module if auto-cycling is enabled and it is not in load shedding mode. If auto-cycling is enabled, and all the control temperature sensors have failed, the control module will still perform an autocycle AUTO-CYCLE TIME INTERVAL Purpose: AUTO-CYCLE INTERVAL is the number of hours/minutes between successive heating circuit integrity tests depending on the AUTOCYCLE UNITS specified. Range: 1 to 240 Procedure: Set the AUTO-CYCLE INTERVAL to the desired time period. IMPORTANT: When using proportional ambient contactor mode, the CYCLE TIME setting should be less than the AUTO-CYCLE INTERVAL otherwise autocycling could affect the duty-cycle. For the earliest possible alarming of heating circuit problems, the AUTO-CYCLE INTERVAL should be set to a small value. This feature is only available if AUTO-CYCLE is enabled. 29 / 81

30 AUTO-CYCLE TIME UNITS Purpose: The AUTO-CYCLE UNITS parameter allows selection of minutes or hours for the AUTO- CYCLE INTERVAL setting. Setting: HOURS or MINUTES Procedure: Set the AUTO-CYCLE UNITS to the desired time units. IMPORTANT: This feature is only available if AUTO-CYCLE is enabled ENABLING LOAD SHEDDING Purpose: The load shedding function allows the control module output to be forced off by a load shedding command issued from a GCC (Model 780/GCC-9000 or AC 2000+). The load shedding feature may be used to turn off the output of one or more control modules in order to reduce energy consumption to avoid peak demand surcharges, remove power from unused heating circuits, or remove power from heating circuits which may be subjected to steam cleaning. Setting: ENABLE or DISABLE Procedure: Enable or disable the load shedding control mode as desired. IMPORTANT: When using the operator interface of a Model 780/GCC-9000 GCC, the GCC itself must first be configured for load shedding operation before any control module may be set up for load shedding control. For a control module configured as an ATC SLAVE, a load shedding command has higher priority than the ATC signal from an ATC MASTER. For a control module configured as an ATC MASTER, a load shedding command does not affect its ATC output signal. When using an AC 2000, a Model 780/GCC-9000 GCC must be used to set up the following additional parameters to completely configure the control module for load shedding operation: FAIL SAFE MODE, LOAD SHEDDING GCC CONTACTS ENABLING FAIL SAFE MODE Purpose: Fail safe mode is used to protect a heating circuit from freezing if the control module s output is off due to a load shedding command issued by a GCC. Once the temperature of the TS used in the TS CONTROL MODE drops to that sensor s LOW TEMP ALARM setting, the control module s output will go on. Setting: ENABLE or DISABLE Procedure: The FAIL SAFE MODE parameter must be enabled or disabled based on the application requirements. If FAIL SAFE MODE is enabled, then at least one LOW TS TEMP ALARM (of a TS used in the TS CONTROL MODE) must be enabled, and its LOW TS TEMP ALARM temperature must be less than the CONTROL SETPOINT temperature. Otherwise, the control module will not go into load shedding mode. If disabled and load shedding is active, the control module will keep the output off regardless of the measured temperature. IMPORTANT: This feature is only available if the load shedding control mode is enabled. For the CM 2000+, FAIL SAFE MODE is always disabled if the SWITCH CONTROL MODE is set to either of the two proportional ambient control modes. If the TS CONTROL MODE uses both TS 1 and TS 2 to calculate the control temperature, the control module will turn its output on if the following conditions are met: Load shedding is active The FAIL SAFE MODE parameter is enabled Both TS 1 and TS 2 have their LOW TS TEMP ALARMS enabled The control temperature falls below either of the LOW TS TEMP ALARM temperatures The ATC output signal is not affected for a control module configured as an ATC MASTER in fail safe operation. The FAIL SAFE MODE parameter should always be disabled for a control module configured as an ATC SLAVE. 30 / 81

31 LOAD SHEDDING GCC CONTACT INPUTS Purpose: This allows the user to specify, which of the four GCC contact inputs will cause this control module to be put into load shedding mode. Each control module may be programmed to respond to any combination of the four GCC contact inputs. For details on the load shedding command issued by a GCC see Section 5.3 of this manual. Setting: ENABLE/YES or DISABLE/NO Procedure: Select ENABLE/YES to enable or DISABLE/NO to disable, the load shedding control associated with a particular GCC contact input. IMPORTANT: This feature is only available if the load shedding control mode is enabled. If a control module is programmed to be associated with more than one of the four GCC contact inputs, then all of the enabled GCC contact inputs must be actuated (in the load shedding command issued by the GCC) before the control module will go into load shedding mode ALARM OUTPUT NORMAL STATE Purpose: This allows the selection of the normal state of the alarm output signal from the control module. This alarm output signal is used to control the alarm relay on the AC 2000 alarm/ communications interface card when the control module detects an alarm condition. The normal state is assumed to be when the control module is powered and no alarms exist. Setting: N.O. (Normally Open) or N.C. (Normally Closed) Procedure: The ALARM OUTPUT NORMAL STATE for the CM 2000 or the CM control modules must always be set for Normally Open (N.O.) operation. This insures that the ALARM LED on the front panel of the AC 2000 Alarm/communications Interface or AI Alarm Interface card will only be illuminated when an alarm condition exists in a control module. IMPORTANT: The coil of the alarm output relay of the AC 2000 alarm/communications interface card will be energized under normal conditions (power on with no control module alarms). Therefore, loss of power or an active alarm on any connected control module will de-energize the alarm output relay. The AC 2000 s Normally Closed (N.C.) contacts will open and its Normally Open (N.O.) contacts will close. The relay drive output(s) of the AC 2000 Alarm/communications Interface or AI Alarm Interface card will be energized under normal conditions (power on with no control module alarms). Therefore, loss of power or an active alarm on any connected control module will de-energize an external output relay FLASH ALARM OUTPUT SETTING Purpose: Programs the alarm output signal from a control module for flashing or steady output in case of an alarm condition. Setting: YES (Flash) or NO (Steady) Procedure: The FLASH ALARM OUTPUT SETTING for the CM 2000 and the CM control modules, must always be set to NO (Steady). If set to YES (Flash) there is the possibility that the ALARM LED and the dry contact alarm output relay on the AC 2000 alarm/communications interface card may not activate if more than one control module has an active alarm. 31 / 81

32 LATCH TEMPERATURE SENSOR ALARMS SETTING Purpose: This allows for the selection of automatic clearing of all HIGH and LOW TS TEMP ALARMS (non-latching) when a temperature alarm condition no longer exists or permanent alarming of such a condition (latching) until the alarm is manually reset. Setting: LATCHING or NON-LATCHING Procedure: Adjust the LATCH TS ALARMS setting to the desired mode (latching or non-latching). IMPORTANT: If your application is subject to periodic situations where cold or hot product is part of the process, it may be appropriate to configure the control module for non-latching temperature alarms to avoid nuisance alarms. If it is important to be aware of any temperature alarm conditions that may have existed in a pipe, then the control module should be configured for latching temperature alarms. This setting does not affect the TS FAILURE ALARMS these are always latching. 3.5 ALARM SETTINGS The sections that follow explain the various alarming parameters of the CM 2000 and the CM control modules. The first line of each section identifies the alarm parameter to be described. Each section goes on to explain the following: Purpose of the alarm parameter Alarm Mask used for enabling the alarm parameter If applicable, the Range over which the alarm setpoint may be set Procedure for setting or enabling the alarm parameter Any Notes or Cautions that pertain to that particular alarm parameter Setting and using the alarming parameters of the control module is a two step procedure: 1. The alarm must be enabled or disabled as desired. Modification of the alarm mask is found in the SETUP section of the Group Communications Controller (Model 780/GCC-9000), the Handheld Programmer (Model 760/HHP-9000), and the Panel Mount Programmer (Model 761). Please see the appropriate operating manual for instructions on accessing these parameters. 2. The corresponding alarm setpoint value may be modified appropriately for the application. Alarm setpoint values, for enabled alarms, can be modified in the SETPOINTS section of the Group Communications Controller (Model 780/GCC-9000), the Handheld Programmer (Model 760/HHP-9000), and the Panel Mount Programmer (Model 761). Please see the appropriate operating manual for instructions on accessing these features. IMPORTANT: If an alarm is disabled, an external upstream programming device will not allow modification of its alarm setpoint value COMMUNICATIONS FAILURE ALARM Purpose: If enabled in the GCC (Model 780/GCC-9000 or AC 2000+), this alarm will be activated when the communications link between the GCC and the control module fails. This alarm is not actually generated in the control module, as are the other alarms. Instead, this alarm is generated by the GCC for the particular control module being interrogated. This alarm can be disabled thus allowing the GCC to ignore this control module if it does not respond. Alarm Mask: ENABLE or DISABLE Procedure: Selecting enable will provide notification that the control module is not responding to the GCC. Loss of communication with the GCC will not prevent the control module from operating. However, none of the control module s parameters can be read or modified HIGH TS 1 TEMPERATURE ALARM Purpose: If enabled, the HIGH TS 1 TEMP ALARM allows for alarming of high temperature conditions as sensed by the temperature sensor connected to the RTD1 input. Alarm Mask: ENABLE or DISABLE Range: 76 to 1058 F ( 60 to 570 C) Procedure: Adjust the HIGH TS 1 TEMP ALARM temperature setpoint to the desired value. Note that the HIGH TS 1 TEMP ALARM must be enabled in order to adjust the HIGH TS 1 TEMP ALARM temperature setpoint. 32 / 81

33 IMPORTANT: This alarm should only be used for applications where a product that is sensitive to over temperature is involved. General usage may result in nuisance alarms due to the flow of hot product or steam out. This may be a case where the alarm should be enabled and non-latching temperature alarming should be used. A high temperature condition resulting from a forced on failure of the heating circuit should first be alarmed by the SWITCH FAILURE ALARM (see Section for more information) LOW TS 1 TEMPERATURE ALARM Purpose: If enabled, the LOW TS 1 TEMP ALARM allows for alarming of low temperature conditions as sensed by the temperature sensor connected to the RTD1 input. Alarm Mask: ENABLE or DISABLE Range: 76 to 1058 F ( 60 to 570 C) Procedure: Adjust the LOW TS 1 TEMP ALARM temperature setpoint to the desired value. Note that the LOW TS 1 TEMP ALARM must be enabled in order to adjust the LOW TS 1 TEMP ALARM temperature setpoint. IMPORTANT: This alarm should normally be enabled and the setpoint should be appropriate for the heating application. Maintaining a minimum 9 F (5 C) differential between the LOW TS 1 TEMP ALARM temperature setpoint and the CONTROL SETPOINT temperature will minimize nuisance alarming due to momentary dips in temperature. Another alternative to this is to configure the control module to use non-latching temperature alarming. This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT temperature if the load shedding fail safe mode uses the TS 1 temperature reading TS 1 FAILURE ALARM Purpose: Enabling the TS 1 FAILURE alarm will provide an indication of an open or shorted failure of the temperature sensor connected to the RTD1 input. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable alarming of a failed temperature sensor connected to the RTD1 input as required. IMPORTANT: This failure alarm should be enabled if a temperature sensor is connected to the RTD1 input. This alarm is always latched and must be reset by the user HIGH TS 2 TEMPERATURE ALARM Purpose: If enabled, the HIGH TS 2 TEMP ALARM allows for alarming of high temperature conditions as sensed by the temperature sensor connected to the RTD2 input. Alarm Mask: ENABLE or DISABLE Range: 76 to 1058 F ( 60 to 570 C) Procedure: Adjust the HIGH TS 2 TEMP ALARM temperature setpoint to the desired value. Note that the HIGH TS 2 TEMP ALARM must be enabled in order to adjust the HIGH TS 2 TEMP ALARM temperature setpoint. IMPORTANT: If no second sensor is installed this alarm should be disabled. This alarm may be used for applications where a product that is sensitive to over temperature is involved. General usage could result in nuisance alarms due to the flow of hot product or steam out. This may be a case where the alarm could be enabled and non-latching temperature alarming used. A high temperature condition resulting from a forced on failure of the heating circuit should first be alarmed by the SWITCH FAILURE ALARM (see Section for more information). 33 / 81

34 3.5.6 LOW TS 2 TEMPERATURE ALARM Purpose: If enabled, the LOW TS 2 TEMP ALARM allows for alarming of low temperature conditions as sensed by the temperature sensor connected to the RTD2 input. Alarm Mask: ENABLE or DISABLE Range: 76 to 1058 F ( 60 to 570 C) Procedure: Adjust LOW TS 2 TEMP ALARM temperature setpoint to the desired value. Note that the LOW TS 2 TEMP ALARM must be enabled in order to adjust the LOW TS 2 TEMP ALARM temperature setpoint. IMPORTANT: If no second sensor is installed this alarm should be disabled. This alarm should be enabled and the setpoint should be appropriate for the heating application. Maintaining a minimum 9 F (5 C) differential between the LOW TS 2 TEMP ALARM temperature setpoint and the CON- TROL SETPOINT temperature will minimize nuisance alarming due to momentary dips in temperature. Another alternative to this is to configure the control module to use non-latching temperature alarming. This alarm must be enabled and its setpoint must be below the CONTROL SETPOINT temperature if the load shedding fail safe mode uses the TS 2 temperature reading TS 2 FAILURE ALARM Purpose: Enabling the TS 2 FAILURE alarm will provide an indication of an open or shorted failure of the temperature sensor connected to the RTD2 input. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable alarming of a failed temperature sensor connected to the RTD2 input as required. IMPORTANT: If no second sensor is installed, this alarm should be disabled. This failure alarm should be enabled if a second temperature sensor is connected to the RTD2 input. This alarm is always latched and must be reset by the user CONTROL TS FAILURE ALARM Purpose: Control TS FAILURE ALARM indicates a failure of the temperature sensor designated as the control sensor. When this condition is present, the three-character display will always flash tsf with the TEMP status LED illuminated. The selected TS CONTROL MODE determines which RTD input(s) will be designated to provide the control temperature. See Section for a full description of the temperature sensor control designations. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable the alarming of a failure of the designated control temperature sensor as required. IMPORTANT: This alarm should always be enabled. If the control module experiences a Control TS Failure it will turn the output off until this alarm is cleared. This is a latching alarm unless the selected TS CONTROL MODE is ATC SLAVE then it is a nonlatching alarm and the load shedding fail safe mode is always disabled HIGH LOAD CURRENT ALARM Purpose: Alarms current levels, which are higher than a preset limit for the application. Alarm Mask: ENABLE or DISABLE Range: 0.3 to 60.0 A for CM to 120% of SWITCH CURRENT RATING for CM 2000 (CURRENT TURNS RATIO = 1.00) 34 / 81

35 Procedure: Adjust the HIGH CURRENT ALARM level to the desired value. Note that the HIGH CURRENT ALARM must be enabled in order to adjust the HIGH CURRENT ALARM level. Also note that the HIGH CURRENT ALARM level is affected by the CURRENT TURNS RATIO setting. The absolute maximum adjusted HIGH CURRENT ALARM level is A. The absolute minimum adjusted HIGH CURRENT ALARM level is 0.1 A. See Section for more information regarding the CURRENT TURNS RATIO function. IMPORTANT: The HIGH CURRENT ALARM does not necessarily have to be enabled for control modules using PROPORTIONAL or PROPORTIONAL AMBIENT SSR control modes, since they will attempt to automatically protect themselves from overload. The HIGH CURRENT ALARM can be used effectively to guard against accidental paralleling of heating circuits. In-rush, or cold start currents typically associated with self-regulating cables may cause nuisance HIGH CURRENT ALARMS. If this is undesirable this alarm should be disabled LOW LOAD CURRENT ALARM Purpose: Alarms current levels, which are lower than a preset limit for the application. Monitoring for lower than expected current levels may be an effective means of continuity monitoring. Alarm Mask: ENABLE or DISABLE Range: 0.3 to 60.0 A for CM to 120% of SWITCH CURRENT RATING for CM 2000 (CURRENT TURNS RATIO = 1.00) Procedure: Adjust the LOW CURRENT ALARM level to the desired value. Note that the LOW CURRENT ALARM must be enabled in order to adjust the LOW CURRENT ALARM level. Also note that the LOW CURRENT ALARM level is affected by the CURRENT TURNS RATIO setting. The absolute maximum adjusted LOW CURRENT ALARM level is A. The absolute minimum adjusted LOW CURRENT ALARM level is 0.1 A. See Section for more information regarding the CURRENT TURNS RATIO function. IMPORTANT: (for CM 2000 only) To minimize nuisance LOW CURRENT ALARMS, the CM 2000 control module must detect a current level less than the LOW CURRENT ALARM setpoint for a period longer than approximately 20 consecutive seconds. For series type heating cables, adjusting the LOW CURRENT ALARM to 50% of full load current will properly alarm a problem and reduce nuisance alarms due to voltage dips. Parallel heaters should be adjusted to a level as close as possible to full load current but lower than the current at worst case voltage. The low current setting as a percentage of full load current will vary depending on the facility and its power system. A LOW CURRENT ALARM may also result from a switch failed open. The control module cannot detect a switch failure due to no current. A no current condition would be identified by a LOW CURRENT ALARM (if enabled) and the analog value reported with the alarm will be 0.0 A HIGH GROUND FAULT CURRENT ALARM Purpose: Alarms ground fault current levels, which are higher than a preset limit for the application. Alarm Mask: ENABLE or DISABLE Range: 20 to 100 ma Procedure: Adjust the HIGH GFI ALARM level to the desired value. Note that the HIGH GFI ALARM must be enabled in order to adjust the HIGH GFI ALARM level. 35 / 81

36 GROUND FAULT TRIP ALARM Purpose: This value sets the upper limit of allowable ground fault leakage current. Exceeding this limit will result in the output switch being latched off and the GFI TRIP ALARM activated to indicate a ground fault condition. In addition, the three-character display will display gfi when the load current would normally be displayed, and the CURRENT status LED will be flashing when the TEMP and SETPT status LEDs are illuminated. Alarm Mask: ENABLE or DISABLE Range: 20 to 100 ma Procedure: If ground fault tripping is desired, enable the GFI TRIP ALARM and adjust the G.F. TRIP CURRENT to the desired value. To disable ground fault tripping, disable the alarm. Note that the GFI TRIP ALARM must be enabled in order to adjust the G.F. TRIP CURRENT level. WARNING: Fire Hazard A ground-fault alarm may mean the heating cable has been damaged or improperly installed and must not be ignored. Sustained electrical arcing or fire can result. To minimize the risk of fire if the alarm has tripped, shut off the power to the heating cable and repair the system immediately. IMPORTANT: In order to implement a ground fault trip function, all non-grounded power conductors must be opened upon detection of a ground fault condition. National Electrical Codes may require that all legs of non-neutral based power sources be opened upon detection of a Ground Fault. Multi-pole switch configurations should be used on non-neutral based power systems. Check the requirements with your local Electrical Authority HIGH VOLTAGE ALARM Purpose: Alarms voltage levels which are higher than a preset limit for the application. Serves as a monitor of the voltage used to power the heating circuit. Alarm Mask: ENABLE or DISABLE Range: 90 to 280 Volts (VOLTAGE TURNS RATIO = 1.00) Procedure: Adjust the HIGH VOLTAGE ALARM level to the desired value. Note that the HIGH VOLTAGE ALARM must be enabled in order to adjust the HIGH VOLTAGE ALARM level. Also note that the HIGH VOLTAGE ALARM level is affected by the VOLTAGE TURNS RATIO setting. The absolute maximum adjusted HIGH VOLTAGE ALARM level is 1000 Volts. The absolute minimum adjusted HIGH VOLTAGE ALARM level is 9 Volts. See Section for more information regarding the VOLTAGE TURNS RATIO function LOW VOLTAGE ALARM Purpose: Alarms voltage levels, which are lower than a preset limit for the application. Alarm Mask: ENABLE or DISABLE Range: 90 to 280 Volts (VOLTAGE TURNS RATIO = 1.00) Procedure: Adjust the LOW VOLTAGE ALARM level to the desired value. Note that the LOW VOLTAGE ALARM must be enabled in order to adjust the LOW VOLTAGE ALARM level. Also note that the LOW VOLTAGE ALARM level is affected by the VOLTAGE TURNS RATIO setting. The absolute maximum adjusted LOW VOLTAGE ALARM level is 1000 Volts. The absolute minimum adjusted LOW VOLTAGE ALARM level is 9 Volts. See Section for more information regarding the VOLTAGE TURNS RATIO function. IMPORTANT: It is recommended that the LOW VOLTAGE ALARM always be enabled OVERCURRENT TRIP ALARM (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the overcurrent trip feature is always enabled when using proportional or proportional ambient SSR control modes with an SSR output switch. This feature is used to provide protection for the output switch. Enabling this alarm will only inform the user of an excessively high current condition and that the output switch has been latched off. During a high current condition, the control module attempts to soft start a heating cable using a technique involving measured in-rush current and the SWITCH CURRENT RATING. If the control module is unable to start the cable, it will eventually trip its output switch off and will not retry or pulse its output switch again. At this point the OVERCURRENT TRIP 36 / 81

37 ALARM is latched on and the three-character display will display trp when the load current would normally be displayed, and the CURRENT status LED will be flashing when the TEMP and SETPT status LEDs are illuminated. IMPORTANT: The control module is NOT a safety cutout or an overcurrent protective device as defined by the National and Canadian Electrical Codes (NEC & CEC). A protective device such as a circuit breaker or fuse must be included as part of a proper design and be selected in accordance with the requirements defined in the National Electrical Code (NEC) and/or the Canadian Electrical Code (CEC). The control module cannot protect the SSR from short circuits or excessive overcurrent conditions. Always ensure that the power is off prior to performing any maintenance or troubleshooting of the heating circuit. Verify that no damage has occurred to the cable or the control module prior to re-energizing the heating circuit. Alarm Mask: ENABLE or DISABLE Procedure: Adjust the SWITCH CURRENT RATING setting to the actual current rating of the SSR. Enable or disable the alarm as required. Note that the OVERCURRENT TRIP ALARM does not have to be enabled in order to adjust the SWITCH CURRENT RATNG setting. IMPORTANT: It is highly recommended that this alarm be enabled since an overcurrent trip condition would normally represent a serious problem. This is a factory set alarm value and disabling the alarm does not disable the overcurrent trip function. In some applications the use of self-regulating cable will produce very high in-rush currents during cold startup. These currents may exceed the overcurrent trip limit and the control module will not be able to soft start the heating circuit. If this condition persists please contact your nearest Pentair Thermal Management sales office for recommendations and solutions to this problem SWITCH FAILURE ALARM Purpose: The purpose of the SWITCH FAILURE ALARM is to indicate that an output switch failure has occurred. The control module determines that if the output switch is turned off and there is load current present, then the output switch has failed closed and the alarm is latched on. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable the alarming of an output switch that has failed in the closed position. IMPORTANT: The SWITCH FAILURE alarm should always be enabled. A high temperature condition, as a result of a failed heating circuit, can only be caused if the output switch fails closed. When an output switch fails closed, the control module cannot turn the power to the heating circuit off, therefore no protection features are available (ground fault trip, power limiting, etc.). If a SWITCH FAILURE ALARM is detected, the unit should be serviced immediately HTC RESET ALARM Purpose: The HTC RESET ALARM is used to indicate: 1. Power to the control module has been interrupted and subsequently restored. 2. A transient has caused the control module s microprocessor to restart its program. 3. An internal condition has caused the control module s microprocessor to restart its program. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable alarming on reset as desired. IMPORTANT: Normally the HTC RESET ALARM is left disabled since powering the control module off and on for maintenance or trouble-shooting would require the user to reset this alarm every time. If the particular installation includes an external upstream programming device, this alarm may be left enabled since resets are not considered normal occurrences and the external upstream programming device provides the capability to easily log and reset these alarms. The time difference between when a Communications FaiLURE ALARM and an HTC Reset ALARM are 37 / 81

38 logged provides an indication of how long the heating circuit has been off CIRCUIT BREAKER LIMITING STATUS (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the circuit breaker limiting feature is always enabled when using proportional or proportional ambient SSR control modes with an SSR output switch. This feature is intended to prevent the circuit breaker immediately upstream of the control module from tripping during a temporary overcurrent condition. Enabling this alarm will only inform the user that circuit breaker limiting is currently active. Alarm Mask: ENABLE or DISABLE Procedure: Adjust the CIRCUIT BREAKER CURRENT RATING setting to the heating circuit breaker size (i.e or 20.0 A). Enable or disable this alarm as required. Note that the CIRCUIT BREAKER LIMITING ALARM does not have to be enabled in order to adjust the CIRCUIT BREAKER CURRENT RATING setting. IMPORTANT: This is a non-latching alarm. This alarm may be considered an advisory alarm. If the measured current exceeds the level that would cause the upstream circuit breaker to release, the control module will begin to switch the SSR on and off rapidly to limit the average current to an acceptable level POWER LIMITING STATUS (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the power limiting feature is always enabled when using proportional or proportional ambient SSR control modes with an SSR output switch. This feature is intended to limit the average amount of power that is applied to the heating circuit. The control module measures the voltage and current of the heating circuit and will vary its output switch to limit the amount of power applied to the heating circuit to the value set by the MAXIMUM POWER setting. Enabling this alarm will only inform the user that power limiting is currently active. Alarm Mask: ENABLE or DISABLE Procedure: Adjust the MAXIMUM POWER setting to the desired value. Enable or disable the alarm as required. Note that the POWER LIMITING ALARM does not have to be enabled in order to adjust the MAXIMUM POWER setting. IMPORTANT: This is a non-latching alarm. This alarm may be considered more appropriately an advisory alarm and is normally disabled. It will be active if the MAXIMUM POWER setting is set below the power output level required for temperature maintenance. In other words, if the heating circuit demands the maximum power allowed and the alarm is enabled, then this alarm will be indicated and the output switch will pulse on and off to limit the average power output to a value approximately equal to the MAXIMUM POWER setting SWITCH LIMITING STATUS (SSR ONLY) Purpose: If a control module is not configured as an ATC SLAVE, the switch limiting feature is always enabled when using proportional or proportional ambient SSR control modes with an SSR output switch. This feature is intended to provide protection for the output switch. Enabling this alarm will only inform the user that switch limiting is currently active and an excessively high current condition is present. The control module pulses its output switch for a small number of cycles and reads the resulting current. If the measured current exceeds the SWITCH RATING setting, then the duty-cycle of its output switch will be varied so that an average current not exceeding the SWITCH RATING setting is maintained. Alarm Mask: ENABLE or DISABLE Procedure: Adjust the SWITCH CURRENT RATING setting to the actual current rating of the SSR. Enable or disable the alarm as required. Note that the SWITCH LIMITING ALARM does not have to be enabled in order to adjust the SWITCH CURRENT RATNG setting. IMPORTANT: This is a non-latching alarm. This alarm should normally be left enabled. Currents in this range cannot be considered 38 / 81

39 normal and should be investigated CONTACTOR COUNT ALARM (CM ONLY) Purpose: Generates an alarm if the number of off-to-on transitions of a contactor reaches or exceeds the CONTACTOR COUNT ALARM setting. This serves as a method to perform preventative maintenance on the contactor before a failure is likely to occur. Alarm Mask: ENABLE or DISABLE Range: 0 to off-to-on transitions Procedure: Adjust the CONTACTOR ALARM setting to the desired value. Note that the CONTACTOR ALARM must be enabled in order to adjust the CONTACTOR ALARM setting. IMPORTANT: The CONTACTOR ALARM is only available if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR EEROM DATA FAILURE ALARM Purpose: This alarm indicates that the control module has detected a failure in its non-volatile memory. If this occurs, the control module may be uncalibrated because factory default values may have been reloaded. This indicates an internal problem and the control module should be replaced and returned to the factory for repair. The three-character display will always flash Err when this alarm is active. Alarm Mask: ENABLE or DISABLE Procedure: Enable or disable alarming of a non-volatile memory failure as desired. IMPORTANT: The EEROM DATA FAILURE ALARM should always be enabled. This alarm cannot be reset. 39 / 81

40 SECTION 4 CONTROL MODULE MONITORED PARAMETER DETAILS 4.1 INTRODUCTION 4.2 ANALOG READINGS This section provides a brief summary of each of the measured and calculated parameters that the control module provides to the user. Detailed information regarding settings, alarms limits, etc. may be found in Section 3 of this manual. For detailed information regarding the display of these variables using an external upstream programming device, refer to the appropriate operating manual for that device CONTROL TEMPERATURE Purpose: This is the temperature that the control module uses to determine whether its output switch should be on or off. Depending on the TS CONTROL MODE setting and whether one or two RTDs are installed, the CONTROL TEMPERATURE may be derived from TS 1 or TS 2 or a combination of the two temperatures. See Section of this manual for further details regarding the TS CONTROL MODE settings. IMPORTANT: The CONTROL TEMPERATURE will not be displayed if the control module is configured as an ATC SLAVE TS 1 TEMPERATURE Purpose: This temperature is the value that the control module is reading from the temperature sensor connected to its RTD1 input. Depending on the TS CONTROL MODE, it may be used to determine the CONTROL TEMPERATURE (see Section above). IMPORTANT: If the RTD1 input is not being used by the control module, then the TS 1 TEMPERATURE is not displayed TS 2 TEMPERATURE Purpose: This temperature is the value that the control module is reading from the temperature sensor connected to its RTD2 input. Depending on the TS CONTROL MODE, it may be used to determine the CONTROL TEMPERATURE (see Section above). IMPORTANT: If the RTD2 input is not being used by the control module, then the TS 2 TEMPERATURE is not displayed LOAD CURRENT Purpose: The LOAD CURRENT reading indicates the average current being drawn by the heating cable. IMPORTANT: The control module calculates the LOAD CURRENT using the current sensed by the remote current transformer module (CT 2000) multiplied by the CURRENT TURNS RATIO to yield an adjusted current value GROUND FAULT CURRENT Purpose: If the control module detects any leakage current in the heating circuit, it will indicate the level in ma. IMPORTANT: To minimize nuisance alarms, the control module will not report a leakage current of less than 20 ma VOLTAGE Purpose: The voltage reading indicates the average heating circuit voltage being measured by the control module. IMPORTANT: The control module calculates this parameter using the voltage powering the control module multiplied by the VOLTAGE TURNS RATIO to yield an adjusted voltage value. 40 / 81

41 4.2.7 POWER Purpose: Load power provides an indication of the average power being consumed by the heat trace cable. IMPORTANT: The control module calculates load power by multiplying the average adjusted voltage reading by the average adjusted current reading. Both the VOLTAGE TURNS RATIO and the CURRENT TURNS RATIO affect the load power reading TEST TRACING Purpose: The TEST TRACING feature provides an easy method of turning the output switch on. This is done by temporarily overriding the temperature control, without having to modify the CONTROL SETPOINT temperature or any other configuration parameter. Procedure: Select the TEST TRACING function on the external upstream programming device to force the output switch on for approximately 20 to 30 seconds. After the test time has expired, the unit will automatically revert back to normal operation. IMPORTANT: This feature only overrides the temperature control, it does not override other control parameters such as power limiting. If load shedding is active then the TEST TRACING function is inhibited. 4.3 MAINTENANCE DATA MAX / MIN TEMPERATURE VALUES MAX CONTROL TEMP MIN CONTROL TEMP TS 1 MAX TEMP TS 1 MIN TEMP TS 2 MAX TEMP TS 2 MIN TEMP Purpose: This feature indicates the maximum and minimum temperatures recorded by the control module since the last time the values were reset. It may be useful to log the maximum/minimum temperatures experienced on a particular heating circuit for the purposes of trouble shooting or gathering data for future design criteria. The temperature values are written to the control module s non-volatile memory once every 24 hours or whenever the user resets any maintenance data. Max/min temperatures are recorded for TS 1, TS 2 and the CONTROL TS. Range: Can only be reset (cleared) by the operator. Procedure: The max/min temperatures may be reset using external upstream programming device. See the appropriate manual for the proper procedure. Resetting any one of the temperatures will reset all of them. IMPORTANT: If the control module is configured as an ATC SLAVE then MAX CONTROL TEMP and MIN CONTROL TEMP are not displayed. If the control module does not use a particular temperature sensor then that temperature sensor s MAX TEMP and MIN TEMP are not displayed POWER ACCUMULATOR Purpose: This feature indicates the total power consumption of the heating circuit since the last time the POWER ACCUMULATOR was reset. It may be useful to log the amount of power consumed on a particular heating circuit for the purposes of energy management or gathering of data for future design criteria. The value of this accumulator is written to the control module s non-volatile memory once every 24 hours or whenever the user resets any maintenance data. Procedure: The POWER ACCUMULATOR may be reset to zero using an external upstream programming device. See the appropriate manual for the proper procedure. IMPORTANT: The POWER ACCUMULATOR value will roll over to zero when the upper limit of the POWER ACCUMULATOR has been exceeded. This upper limit for the CM is 214,748,364.7 kw-hours and the upper limit for the CM 2000 is 429,496,729.5 kw-hours. 41 / 81

42 4.3.3 CONTACTOR CYCLE COUNTER (CM ONLY) Purpose: This feature indicates the total number of off-to-on transitions a contactor has made since the last time the CONTACTOR CYCLE COUNTER was reset. This serves as a method to perform preventative maintenance on the contactor according to the manufacturer s specifications. This count value is written to the control module s non-volatile memory once every 24 hours or whenever the user resets any maintenance data. Procedure: The CONTACTOR CYCLE COUNTER may be reset to zero using an external upstream programming device. See the appropriate manual for the proper procedure. IMPORTANT: Once the CONTACTOR CYCLE COUNTER reaches 999,999,999 it will stop counting. The CONTACTOR CYCLE COUNTER is only indicated if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR TIME IN USE Purpose: The purpose of this feature is to indicate the total hours the control module has been in use since its initial operation. It may be useful to log the amount of time a particular control module has been in operation for the purposes of maintenance planning or reliability testing. The value of this accumulator is written to the control module s non-volatile memory once every 24 hours or whenever the user resets any maintenance data. Procedure: The IN USE hours accumulator can be reset to zero using an external upstream programming device. See the appropriate manual for the proper procedure. IMPORTANT: The IN USE hours accumulator value will roll over to zero when the upper limit of the accumulator has been exceeded. This upper limit for the CM is 999,999,999 hours and the upper limit for the CM 2000 is 16,777,215 hours TIME SINCE LAST RESET Purpose: This feature indicates the total hours the control module has been in use since the last reset. For trouble-shooting purposes, it may be useful to log the amount of time a particular control module has been in operation since the last time the control module s power was cycled. Procedure: The TIME SINCE LAST RESET hours accumulator can only be reset by cycling the control module s power. IMPORTANT: The TIME SINCE LAST RESET hours will roll over to zero when the upper limit of 65,535 hours has been exceeded. 42 / 81

43 SECTION 5 CONTROL MODULE CONTROL MODES 5.1 INTRODUCTION 5.2 SWITCH CONTROL MODES There are several different types of control modes in the control module. Some of these modes require further explanation in order to fully understand and implement their operation. This section describes the functionality of all the control modes available in the control module and how to set their associated parameters. If a control module is not configured as an ATC SLAVE, then four different SWITCH CONTROL modes may be selected when using the CM control module and two different SWITCH CONTROL modes may be selected when using the CM 2000 control module. The following text explains these various modes and how they function PROPORTIONAL CONTROL FOR CM 2000 CONTROL MODULES (FOR USE WITH SSRS ONLY) Proportional control on the CM 2000 is implemented as follows: When using the CM 2000 with an SSR to directly control the power applied to the heating circuit, the output may be switched on/off very rapidly. The control module implements proportional temperature control on a cycle by cycle basis (50 or 60 Hz power line cycle). This algorithm monitors the temperature of the heating circuit and compares it to the CONTROL SETPOINT temperature. If the temperature sensed by the control sensor is 2 F (1 C) below the CONTROL SETPOINT temperature, then power is applied to the heating circuit with a duty cycle of 100% -- the control module output is full on. If the temperature sensed by the control sensor is equal to the CONTROL SETPOINT temperature, then the output is turned on with a duty cycle of 50% the output is on half the time. If the temperature sensed by the control sensor is 2 F (1 C) higher then the CONTROL SETPOINT temperature, then the control module output will have a duty cycle of 0% the output will be off. The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0% - 100% band. Proportional Control Temperature Band For CM 2000 Control Modules Control Sensor Temperature Duty Cycle > Setpoint 2 F (1 C) 0% = Setpoint 50% < Setpoint -2 F (-1 C) 100% PROPORTIONAL CONTROL FOR CM CONTROL MODULES (FOR USE WITH SSRS ONLY) Proportional control on the CM is implemented as follows: When using the CM with an SSR to directly control the power applied to a heating circuit, the output may be switched on/off very rapidly. The control module implements proportional temperature control on a cycle by cycle basis (50 or 60 Hz power line cycle). This algorithm monitors the temperature of the heating circuit and compares it to the CONTROL SETPOINT temperature. If the temperature sensed by the control sensor is at or below the CONTROL SETPOINT temperature, then power is applied to the heating circuit with a duty cycle of 100% the control module output is full on. If the temperature sensed by the control sensor is equal to or greater than the CONTROL SETPOINT temperature + the PROPORTIONAL BAND setting, then the control module output will have a duty cycle of 0% -- the output will be off. 43 / 81

44 The temperature of the control sensor is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0% 100% band. Proportional Control Temperature Band For CM Control Modules Control Sensor Temperature Duty Cycle Š Setpoint+proportional band 0% = Setpoint+proportional band/2 50% Setpoint 100% DEADBAND CONTROL (FOR USE WITH CONTACTORS) Deadband control on the CM 2000 and the CM control modules is implemented as follows: When using the control module in an application where it controls a contactor, proportional control cannot be used since this would cycle the contactor too quickly. In these situations, a deadband control algorithm is used. The output duty cycle is not controlled instead, the output is either fully on or completely off. The user may set the DEADBAND value. The control module monitors the temperature of the heating circuit and compares it to the CONTROL SETPOINT temperature as in the proportional control mode. If the temperature sensed by the control sensor is above the CONTROL SETPOINT temperature by more than the DEADBAND value, the output is turned off. If the temperature sensed by the control sensor falls below the CONTROL SETPOINT temperature the output is turned on. This is a very simple control algorithm but it works very effectively in heat trace applications where the temperature of a traced system changes relatively slowly. Deadband Control Temperature Band Control Sensor Temperature Output State > Setpoint+deadband Off Setpoint On When the control sensor temperature is within the deadband, the output does not change its state. Also, when using deadband control, a contactor is not allowed to toggle faster than once every 2 seconds PROPORTIONAL AMBIENT SSR CONTROL (FOR CM MODULES USING SSRS) When a CM control module using an SSR controls its output using the ambient temperature, this control mode should be used. A CM control module implements proportional ambient SSR control as follows: When using SSRs to directly control the power applied to a heating circuit, the output may be switched on/off very rapidly. The control module implements proportional temperature control on a cycle by cycle basis (50 or 60 Hz power line cycle). The control module monitors ambient temperature rather than pipe temperature using the control sensor and compares it to the CONTROL SETPOINT temperature. If the temperature sensed by the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting, then power is applied to the heating circuit with a duty cycle of 100% -- the control module output is fully on. If the temperature sensed by the control sensor is equal to or greater than the CONTROL SETPOINT temperature, then the output will have a duty cycle of 0% -- the control module output will be off. The ambient temperature (using the control sensor) is constantly monitored and the output duty cycle is adjusted proportionally according to where the temperature falls within the 0% - 100% band. Proportional Ambient SSR Control Temperature Band For CM Control Modules Control Sensor Temperature Duty Cycle Š Setpoint 0% = Setpoint-proportional band/2 50% Setpoint-proportional band 100% 44 / 81

45 IMPORTANT: The load shedding fail safe mode is not supported when using proportional ambient SSR control, since ambient temperature is being monitored rather than pipe temperature PROPORTIONAL AMBIENT CONTACTOR CONTROL (FOR CM MODULES USING CONTACTORS) When a CM control module using a contactor controls its output using the ambient temperature, this control mode should be used. A CM control module implements proportional ambient contactor control as follows: The output may not be switched on/off rapidly when using a contactor, so proportional temperature control is implemented by applying the required duty cycle over the selected CYCLE TIME. The output is fully on for a portion of the CYCLE TIME as determined by the calculated duty cycle, and it will be completely off for the remainder of the CYCLE TIME. The duty cycle is calculated each time the output toggles, based on the ambient temperature, PROPORTIONAL BAND setting and the CONTROL SETPOINT temperature setting. The control module monitors ambient temperature rather than pipe temperature and compares it to the CONTROL SETPOINT temperature as in the proportional ambient SSR control mode. If the temperature sensed by the control sensor is at or below the CONTROL SETPOINT temperature minus the PROPORTIONAL BAND setting, then power is applied to the heating circuit with a duty cycle of 100%. The control module output will be fully on for 1/30th of the CYCLE TIME setting before the duty cycle is calculated again. If the temperature sensed by the control sensor is equal to or greater than the CONTROL SETPOINT temperature, then the output will have a duty cycle of 0%. The control module output will be off for 1/30th of the CYCLE TIME setting before the duty cycle is calculated again. Proportional Ambient Contactor Control Temperature Band For CM Control Modules Control Sensor Temperature Duty Cycle Š Setpoint 0% = Setpoint-proportional band/2 50% Setpoint-proportional band 100% 5.3 LOAD SHEDDING CONTROL MODE IMPORTANT: The load shedding fail safe mode is not supported when using proportional ambient contactor control, since ambient temperature is being monitored rather than pipe temperature. Control modules may be put into a load shedding control mode only after receiving a load shedding command issued from a GCC (Model 780/GCC-9000 or AC 2000+). This mode overrides temperature control and forces the output of the control module off until reset by the GCC. If the load shedding feature is enabled in the GCC, the GCC will issue a load shedding command to the control modules at least once every minute. The status of this load shedding command is determined by how the GCC is configured. The Model 780/GCC-9000 GCC can be configured to generate its load shedding commands from the status of its four local contact inputs or from four remote contact inputs. The AC GCC may only be configured to generate its load shedding commands from the status of four remote contact inputs. Each control module may be programmed to respond (i.e.: enter the load shedding mode) to any combination of the four GCC contact inputs. Sections to of this manual give details on setting up the load shedding parameters of the control module. When power is applied to the control module, it determines if the load shedding mode has been enabled. If enabled, the control module immediately enters the load shedding operation (holding its output off) and waits to see if the GCC has issued a load shedding command. The threecharacter display will flash PrI when the load current would normally be displayed. If no load shedding command is received from the GCC, the control module resumes normal operation. If a load shedding command is received, the control module will continue to hold its output off, until one of the following four conditions occurs: 1. The GCC contact input that initiated load shedding deactivates and the GCC issues a load shedding command that will terminate load shedding mode. 45 / 81

46 5.4 AMBIENT TEMPERATURE CONTROL (ATC) MODE 2. Communications are interrupted between the control module and the GCC (as in the case of a damaged communications wire or loss of power to the GCC). Approximately 30 seconds after communications ceases, the control module will return to normal operation. 3. Communications between the control modules and the GCC goes Off-line for at least two minutes (as occurs when the Handheld Programmer (Model 760/HHP-9000) or the Panel Mount Programmer (Model 761) is used to communicate with the control module). 4. Fail safe operation begins. If this occurs the output will go on. However, the three-character display will still flash PrI when the load current would normally be displayed. IMPORTANT: The control module will return to normal operation if communications between the GCC and the control module are disrupted in any way. This will return temperature control to the control module. The control module does not perform a periodic auto-cycle test while in load shedding mode. For the CM control module, fail safe mode is always disabled if the SWITCH CONTROL MODE is set to either of the two proportional ambient control modes. If the FAIL SAFE MODE parameter is enabled, then at least one LOW TS TEMP ALARM (of a TS used in the TS CONTROL MODE) must be enabled. The associated LOW TS TEMP ALARM temperature must be less than the CONTROL SETPOINT temperature, otherwise the control module will not go into load shedding mode. If the TS CONTROL MODE uses both TS 1 and TS 2 to calculate the control temperature, the control module will turn on its output if the following conditions are met: Load shedding is active The FAIL SAFE MODE parameter is enabled Both TS 1 and TS 2 have their LOW TS TEMP ALARMS enabled The control temperature falls below either of the LOW TS TEMP ALARM temperatures For a control module configured as an ATC MASTER, a load shedding or fail safe command does not affect the ATC output signal. For a control module configured as an ATC SLAVE, a load shedding command has higher priority than the ATC signal from an ATC MASTER. The FAIL SAFE MODE parameter should always be disabled for a control module configured as an ATC SLAVE. If a control module is programmed to be associated with more than one of the four GCC contact inputs, then all of the enabled GCC contact inputs must be actuated (in the load shedding command issued by the GCC) before the control module will go into load shedding mode Ambient Temperature Control (ATC) is achieved by at least one control module (ATC MASTER) controlling the outputs of one or more control modules (ATC SLAVES) using an ATC signal. An ATC MASTER has an ambient temperature sensor connected to at least one of its RTD inputs. An ATC SLAVE does not require a temperature sensor to be connected to either of its RTD inputs. This allows a number of tracing points to be controlled using one or more temperature sensors, eliminating the need for temperature sensors on each control module. A control module cannot be both an ATC MASTER and an ATC SLAVE. The ATC signal from an ATC MASTER will either instruct the ATC SLAVES to turn their outputs on or off, or it will be absent. If the ATC signal is absent then the output of an ATC SLAVE will be off. For more information regarding a control module configured as an ATC MASTER see Section For more information regarding a control module configured as an ATC SLAVE see Section The two RTD inputs and the corresponding TS alarm settings of an ATC SLAVE are available for monitoring applications and are not used in controlling the output. 46 / 81

47 SECTION 6 CONTROL MODULE TROUBLESHOOTING 6.1 OPERATOR CHECKS 6.2 COMMON PROBLEM AREAS IMPORTANT: If the control module does not operate properly and is being returned to Pentair Thermal Management for service, information must be provided as to why the unit was removed from service. Contact Pentair Thermal Management for a Return Authorization form and number prior to returning any units for repair. Upon receipt of the control module, or to check the control module for an indication of normal operation, follow the operational procedures shown below. These procedures are designed to familiarize the operator with the control module and to provide an understanding of its operation. In order to determine if a fault is associated with the heat tracing, wiring or the control module, it will be necessary to troubleshoot the wiring and heating circuit. If the fault remains, remove power from the control module and exchange it with another control module. This may require some reprogramming of the new control module. Refer to the following sections for the appropriate topic. If the fault clears, exchange the control module on another heating circuit to determine if the fault moves with the control module. If the fault moves with the control module, verify that the control module has been configured correctly for the application. If the configuration is correct it may be necessary to return the control module to Pentair Thermal Management for evaluation GETTING STARTED In order to access the parameters and data of the CM 2000/CM control module use any of the external upstream programming devices mentioned in Section 1.3. See the appropriate manual for operational details. The control module may be used as an effective trouble-shooting tool to pinpoint problem areas of heating circuits. The following sections describe a few of the more common problem areas, their symptoms, and parameters to check to determine the actual faulty portion of the heating circuit RTDS RTD failures after installation can generally be attributed to incorrect wiring or improper installation of the sensor. Troubleshooting of these failures is a very simple procedure if the proper steps are undertaken in the correct order. Some specific RTD problems and the correct methods for troubleshooting are outlined as follows. 1. TS Failure Alarm(s) If the control module indicates a failure of an RTD: Ensure that the RTD is a 3-wire 100 ohm platinum type. Turn the power to the CONTROL MODULE off before proceeding! Disconnect the RTD wiring from the input terminals. Measure the RTD s resistance between the source and sense leads at the control module (it should not exceed 40 W). Note that the usual color codes for these wires are White-White or White-Black. Excessive lead resistance will cause a TS FAILURE ALARM and must be corrected. Look for loose terminals, excessive lead length, or insufficient extension wire gauge and correct as necessary. Measure the RTD s resistance between the source or sense lead and the common lead of the RTD at the control module (resistance should be between 60 & 330 W depending on the temperature and the lead resistance. See Appendix F. The usual color code for the source lead is Red, and the source and sense leads are usually White or Black. Verify that the RTD is wired correctly - the control modules will always be terminated in the following order: source (White or Black), sense (White or Black), common (Red). When wiring to the card rack, the terminals are marked as follows: 47 / 81

48 Terminal No. Description 7 RTD SHIELD 8 RTD 1 SOURCE (White or Black) 9 RTD 1 SENSE (White or Black) 10 RTD 1 COMMON (Red) 11 RTD 2 SOURCE (White or Black) 12 RTD 2 SENSE (White or Black) 13 RTD 2 COMMON (Red) Ensure that the RTD extension wire shield is terminated at one end only, normally using terminal # 7. IMPORTANT: Some manufacturers use the common Black-White-Red triad color code for the RTD connections. Usually, the RED lead is the common connection (same as the White-White-Red color scheme) and the White and Black connections may be used interchangeably. 2. Seemingly Incorrect Temperature If you feel that the indicated or displayed temperature is not correct, the control module and the RTD can be quickly checked for correct operation. To verify the RTD: Turn the power to the CONTROL MODULE off before proceeding! Disconnect the RTD wiring from the input terminals. To calculate the temperature indicated by the RTD, measure the resistance from source (white wire) or sense (white or black wire) to common (red wire) and subtract the resistance measured between source and sense. This will give a compensated resistance value that can be crossreferenced to the RTD table found in Appendix F. Compare the measured resistance and crossreferenced temperature value obtained from the RTD table to the indicated or displayed value. These should agree to within the accuracy standards of the control module and the RTD. To verify the control module: Turn the power to the CONTROL MODULE off before proceeding! Disconnect the RTD wiring from the input terminals. Connect a 100 W resistor across the source or sense terminal and common. Insert a jumper between the source and sense terminals. Apply power to the control module. The indicated or displayed temperature should be approximately 32 F (0 C) depending on the actual resistance of the test resistor. 3. Unstable or Bouncing Temperature An erratic indication of temperature may be caused by several factors external to the control module, however a bouncing temperature of a few degrees should not be confused with incorrect operation. The control module s accuracy and resolution will result in an indicated temperature change of a couple of degrees if the measured resistance temperature falls between two discrete values (this is sometimes referred to as quantization error). If the bounce or instability is excessive, check: Wire used for extension of the RTD should be three-wire, twisted and shielded with the shield grounded at the card rack only. Each of the three lead wires must be of the same gauge. The ideal installation has a separate conduit for the RTD leads (if they have been extended). It is not usually a problem to run low signal levels in the same conduit as the power leads even in high power applications, as long as the RTD wire is a twisted, shielded type with an insulation rating equal to or greater than the highest voltage in the conduit. Follow the proper Electrical Code requirements for your particular installation. Terminal connections that are not tight can add resistance to an RTD circuit. Check the tightness of all screw terminal connections at time of installation and during subsequent maintenance checks. Check the specifications for the particular cable being used to ensure that it does not have excessive capacitance when used in long lengths. This can cause a temperature offset between what the control module reads and what the RTD actually measures. This again is normally not a problem since the control module compensates for all but the worst cases of this. 48 / 81

49 Lastly, it is possible for the RTD itself to fail on an intermittent basis but this failure mode should be considered unusual. This kind of failure is probably the most difficult to find but fortunately it is also the least likely failure mechanism GROUND FAULT Ground fault alarms can be due to incorrect installation as well as current leakage resulting from wet system components or faulted cables. WARNING: Fire Hazard A ground-fault alarm may mean the heating cable has been damaged or improperly installed and must not be ignored. Sustained electrical arcing or fire can result. To minimize the risk of fire if the alarm has tripped, shut off the power to the heating cable and repair the system immediately. The control module detects ground faults by summing the outgoing and return trace currents through a current transformer. Under normal operating conditions (no ground fault condition) this current will be zero. When there is a flow of current from one of the trace supply wires to ground, a ground fault condition occurs. If a ground fault alarm is present on start-up of a new installation it is likely due to a wiring error or damaged cable. To verify this condition: Check that the heating circuit neutral conductor returns to the control module s current transformer and is not connected directly to the distribution panel. On paralleled heating circuits, be certain that all neutrals return. The late addition of a heating circuit may not be obvious. The monitoring feature of an external programming device may be used to view the measured ground fault current. If this value is at the maximum that the control module can measure, it is usually an indication that the wiring is incorrect. If the value is less than 100 ma then an actual ground fault condition may exist in the cable or associated wiring. IMPORTANT: The control module monitors the integrity of the ground fault (GF) detection transformer and associated wiring. If a fault is detected, the control module will report a GF value 49 / 81

50 of 300 ma. 6.3 COMMON ALARMS WHAT TO LOOK FOR The CM 2000 and the CM control modules have a wide range of alarming features that may be selectively enabled or disabled to allow the monitoring and indication of trouble conditions. Described below are the different alarm conditions available on the control module, their meanings, and possible causes. Alarm Description Cause of Alarm High TS 1/ TS 2 Temperature This alarm will appear when the sensor temperature exceeds the HIGH TS TEMP ALARM temperature setting. Alarm temperature setting too close to maintain temperature Flow of hot product Steaming out lines Incorrect tracer wiring Low TS 1/TS 2 Temperature TS 1/ TS 2 Failure Control TS Failure High Current Low Current High GFI This alarm will appear when the sensor temperature decreases below the LOW TS TEMP ALARM temperature setting. This alarm will indicate if a temperature sensor is not operating properly. The temperature sensor may fail due to an open or shorted condition. This alarms a failure of the temperature sensing element designated as the control element by the TS CONTROL MODE setting. The output switch may be latched off until this failure is corrected. This alarms current levels that are greater than the HIGH CURRENT ALARM setting for the application. This alarms current levels that are less than the LOW CURRENT ALARM setting. This alarms ground fault current levels which are greater than the HIGH GFI ALARM setting. Alarm temperature setting too close to maintain temperature Flow of cold product Empty Pipe Damaged, wet, or missing insulation Heating cable not sized properly for the application or damaged Incorrect or damaged field wiring - open leads or excessive resistance, (either intermittent or continuous) may be due to broken or damaged wires or loose terminals. Damaged or inoperative temperature sensors Incorrect or damaged field wiring - open leads or excessive resistance (either intermittent or continuous) may be due to broken or damaged wires or loose terminals. Damaged or inoperative temperature sensors The ATC signal from an ATC MASTER control module is absent Alarm setting too close to normal operating current High in-rush current from cold start of self-regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Incorrect wiring Alarm setting too close to normal operating current Low source voltage Damaged or inoperative heating cable Open connection - wiring problem SSR or contactor failure (open) Incorrect CURRENT TURNS RATIO setting Alarm setting too close to normal leakage current Damaged cable insulation and/or moisture present Moisture in junction box Poor splice or termination Moisture provides conductive ground path which allows ground fault current 50 / 81

51 6.3 COMMON ALARMS WHAT TO LOOK FOR The CM 2000 and the CM control modules have a wide range of alarming features that may be selectively enabled or disabled to allow the monitoring and indication of trouble conditions. Described below are the different alarm conditions available on the control module, their meanings, and possible causes. Alarm Description Cause of Alarm GFI Trip High Voltage Low Voltage This value sets the upper limit of allowable ground fault leakage. Exceeding this limit will result in the output switch being latched off and the alarm activated to indicate a ground fault condition. This alarms voltage levels that are greater than the HIGH VOLTAGE ALARM setting. This alarms voltage levels that are less than the LOW VOLTAGE ALARM setting. Trip setting too close to normal leakage current Damaged cable insulation and/or moisture present Moisture in junction box Poor splice or termination Moisture provides conductive ground path which allows ground fault current Alarm setting too close to normal operating voltage Incorrect wiring Power Surge Incorrect VOLTAGE TURNS RATO setting Alarm setting too close to normal operating voltage Damaged power cable Brown-out conditions Loss of power to the heating circuit Incorrect VOLTAGE TURNS RATO setting Overcurrent Trip Switch Failure HTC Reset C.B. Limiting Power Limiting If the control module is unable to start the cable due to high current or after attempting to soft start it, the control module will trip its output switch off. This alarm will indicate that the control module senses current flow when the output switch should be off. This alarm is latched when power is restored after an interruption. Used to identify intermittent power losses. This alarm indicates that the solid-state relay is limiting the average current that is applied to the heating circuit to the C.B. CURRENT RATING setting to protect the heater s upstream circuit breaker from tripping. This alarm indicates that the solid-state relay is limiting the average amount of power that is applied to the heating circuit as defined by the MAXIMUM POWER setting. SWITCH RATING setting is too low High in-rush current from cold start of self-regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Incorrect wiring Some other device energized heat trace Output switch has failed closed Circuit breaker tripped Power line transient C.B. CURRENT RATING setting is too low for normal heater current draw or not matched to actual circuit breaker size High in-rush current from cold start of self-regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Incorrect wiring MAXIMUM POWER setting is too low for normal heater power consumption High in-rush current from cold start of self-regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Incorrect VOLTAGE TURNS RATIO setting Power Surge Incorrect wiring 51 / 81

52 6.3 COMMON ALARMS WHAT TO LOOK FOR The CM 2000 and the CM control modules have a wide range of alarming features that may be selectively enabled or disabled to allow the monitoring and indication of trouble conditions. Described below are the different alarm conditions available on the control module, their meanings, and possible causes. Alarm Description Cause of Alarm Switch Limiting Contactor Count (CM Only) EEROM Data Failure This alarm indicates that the control module is limiting the average current that is applied to the heating circuit based on the SWITCH RATING setting to protect the solid-state relay from excess current. This alarm indicates that the number of off-toon transitions of a contactor has exceeded the CONTACTOR COUNT ALARM setting and the contactor should be replaced. This alarm indicates that the control module has detected a failure in its non-volatile memory. This indicates an internal problem and the control module should be replaced and returned to the factory for repair. SWITCH RATING setting is lower than actual current rating of SSR High in-rush current from cold start of self-regulating cable Damaged or partially shorted heating cable As built cable length is greater than design value Incorrect CURRENT TURNS RATIO setting Incorrect wiring Alarm setting is incorrect Contactor has been controlling the heating circuit for a long time Some configuration parameter (i.e. DEADBAND, AUTO-CYCLE INTERVAL, load shedding etc.) is causing the contactor to toggle more than usual. The control module cannot bypass the failed area of its memory and has loaded factory defaults into this failed area. IMPORTANT: This alarm cannot be reset. 52 / 81

53 SECTION 7 AC PROGRAMMING AND CONFIGURATION 7.1 INTRODUCTION 7.2 INITIAL CONFIGURATION This section provides complete operating and programming details for the AC alarm/ communications interface card. Please see Section 1.5 of this manual for an overview of the AC Before the AC alarm/communications interface card can be used to interface an external programming device with DigiTrace T2000 HTC control modules, the AC communication ports must be configured. This is accomplished by connecting a Personal Computer (PC) to the local front panel RS-232 port using a standard serial communications cable and running the Communication Controller Configuration Utility program (see Section 1.5.3). This program will allow the user to set up all of the communication parameters for each communications port on the AC To set up the AC communication parameters, follow the procedure outlined below: 1. Remove the AC from the card rack. 2. Set the dip switches, located along the top edge of the AC (see Figure 7-1), as follows: E1, E5 Closed E2, E3, E4, E6 Open 3. Insert the AC back into the card rack. 4. Observe the STATUS LED located on the front panel of the AC The following defines the various conditions indicated by the STATUS LED when the AC is in the CONFIGURATION mode: Flashing Amber (expected color): The AC is in Configuration Mode. Proceed to step 5. Flashing Amber and Red: The AC is in Configuration Mode but an internal failure has occurred. All previously saved configuration data was found to be corrupt and default values are being used. The user must re-configure the AC as outlined in step 5. Once any configuration data parameter of the AC has been modified, the STATUS LED will flash amber only. Green: The AC is in Run Mode not in Configuration Mode. Verify that dip switch E1 is closed and make sure the AC is correctly inserted into left-most slot of the card rack. Red or Off: The AC is in Configuration Mode but an internal failure has occurred. The AC should be returned to Pentair Thermal Management for service. 5. Run the Communication Controller Configuration Utility program, and set up the AC communications parameters as described in the Communication Controller Configuration Utility, Installation and Operating Instructions (see Section 1.5.3). 6. When all of the AC s communication parameters have been set up as desired, remove the AC from the card rack. 7. Open the dip switch labeled E1 that was closed in step 2. The dip switches should now be set as follows: E5 Closed E1, E2, E3, E4, E6 Open 8. Insert the AC back into the card rack. 9. Again, observe the STATUS LED located on the front panel of the AC The following defines the various conditions indicated by the STATUS LED when the AC is in the RUN mode: Green (expected color): The AC is in Run Mode and may be used with external devices to communicate with DigiTrace T2000 HTC control modules. Flashing Green and Red: The AC is in Run Mode but an internal failure has occurred. 53 / 81

54 All previously saved configuration data was found to be corrupt and default values are being used. The user must re-configure the AC beginning at step 1. Flashing Amber: The AC is still in Configuration Mode not in Run Mode. Verify that dip switch E1 is open and make sure the AC is correctly inserted into left-most slot of the card rack. Red or Off: The AC is in Run Mode but an internal failure has occurred. The AC should be returned to Pentair Thermal Management for service DIP SWITCH SETTINGS There are six dip switches located along the top edge of the AC (see Figure 7-1). The function of each dip switch is described in the following table: Dip Switch Function E1 Configuration Mode Active When Closed E2 Not Used E3 Not Used E4 Break Mode Active When Closed E5 Watch Dog Timer Enabled When Closed E6 Manual Reset Active When Closed DIP SWITCH OPEN AC Figure 7-1 Dip switch Location on AC D INPUT/OUTPUT PORTS HTC COMMUNICATION PORT The AC alarm/communications interface card can communicate with both the CM 2000 and the CM control modules through its HTC communication port. A TRANSMIT LED and a RECEIVE LED are located on the front panel of the AC to indicate activity on this port. The following descriptions give details on all of the different control module combinations supported by the AC 2000+: Used With CM 2000 Control Modules Only: A maximum of 40 CM 2000 control modules may be used with a single AC The communications rate must be set to 300 baud. Used With CM Control Modules Only: A maximum of 256 CM control modules may be used with a single AC The communications rate may be set to 9600 baud (recommended) or 300 baud. 54 / 81

55 Used With A Mixture of CM 2000 and CM Control Modules: The AC can interface with both CM 2000 and CM control modules simultaneously. However, a maximum of 40 control modules may only be used with a single AC and a data rate of 300 baud must be used RELAY DRIVER OUTPUTS The AC is equipped with two relay driver outputs. One is for indicating Alarm conditions, and the other for indicating Warning conditions. These relay driver outputs ( ma max.) are intended to drive external 12Vdc coil relays connected to local annunciators. They operate in a fail-safe mode, meaning that they are normally energized when the AC is powered up and there are no active alarm or warning conditions. Both outputs have an LED on the front panel of the AC to indicate their status. See Appendix B7 for typical electrical connections LOCAL/REMOTE COMMUNICATION PORTS The AC is equipped with three communication ports to interface with external programming devices supporting the ModBus protocol (such as a PC, PLC or DCS). All DigiTrace T2000 HTC parameters and data may be accessed through any of these three communication ports, using either Page or Linear Modbus Mapping. Complete documentation for the serial communications interface to the AC is described in the Group Communications Controller: Modbus Protocol Interface Page Mapping and in the Group Communications Controller: Modbus Protocol Interface Linear Mapping documents which may be ordered from your nearest Pentair Thermal Management sales office. The following descriptions give details of each of these three communication ports: Remote Port: The remote port s RS-485 interface allows several AC devices to be multi-dropped onto the same pair of communication wires and then connected to a remote programming device such as a host computer, PLC or DCS. This is an isolated, 2-wire, RS-485 serial port that may be connected on the back panel of both the CR 2000 and CR card racks. Both the ASCII and RTU modes of the ModBus communications protocol are supported to a maximum data rate of 9600 baud. TRANSMIT and RECEIVE status LEDs are located on the front panel of the AC to indicate communication activity on this port. IMPORTANT: The AC may only be configured to use either the Remote Port or the Ethernet Port at any one time. Local Port: This port can be configured to use one of two serial interface types. Either a non-isolated, 2-wire, RS-485 serial interface located on the back panel of the CR card rack, or an RS-232 serial interface located on the front panel of the AC Only one of these two interfaces may be used at any one time. The RS-232 interface may be used to connect with one Personal Computer, PLC or DCS in close proximity to the AC The RS-485 interface allows several AC devices to be multi-dropped onto the same pair of RS-485 communication wires and connected to an external RS485, ModBus master device. Both the ASCII and RTU modes of the Modbus communications protocol are supported to a maximum data rate of 9600 baud. TRANSMIT and RECEIVE status LEDs are located on the front panel of the AC to indicate communication activity on this port. Ethernet Port: When remote access to DigiTrace T2000 HTC parameters and data is required using an Ethernet Local Area Network (LAN) this port is used. The Ethernet Port is located on the back panel of the CR card rack and provides an industry-standard 10Base-T interface. The software communications protocol supported by the Ethernet Port is Modbus/TCP. LINK and ACTIVITY status LEDs are located on the front panel of the AC to indicate communication activity on this port. IMPORTANT: The AC can only be configured to use either the serial Remote Port or the Ethernet Port at any one time. 55 / 81

56 7.4 OPERATIONAL CONFIGURATION IMPORTANT: Before the AC alarm/communications interface card can be used to interface an external upstream programming device with DigiTrace T2000 HTC control modules, the AC communication ports must be configured as described in Section 7.2. The following sections give details of the configuration parameters for the AC alarm/ communications interface card. These parameters can only be accessed using one of the AC s communication ports, in conjunction with an external upstream programming device that communicates using the Modbus serial or Modbus/TCP protocols. See Section for additional details regarding the Modbus mapping specific to the AC AC TAG When adding or editing the AC Tag, only the following characters may be used: / -. ( ) # any upper case letter in the alphabet, and any number from 0 to 9. The Tag is always terminated with a space character. IMPORTANT: Tags must be at least one character in length and are limited to a maximum of 19 characters. When an external upstream programming device is communicating to several AC devices sharing the same communication wires, ensure that each AC has a unique Tag LOAD SHEDDING CONTROL This parameter can be ENABLED or DISABLED and determines whether or not the AC will issue load shedding commands to the control modules. Load shedding commands, issued by the AC 2000+, are initiated by sending remote contact input information, using a Modbus command, from an external upstream programming device to the AC In selected control modules, a load shedding command will override their temperature control and force their outputs off until reset by the AC See Sections to , 5-3, 7-4-3, , and as well as Appendix E in this manual for details regarding the load shedding features and the related parameters LOAD SHEDDING ZONES If the LOAD SHEDDING CONTROL parameter of the AC is enabled, then a load shedding command issued by the AC can force control modules into load shedding mode. Four different load shedding zones may be defined, to allow groups of control modules to be forced into load shedding mode simultaneously. If a zone is not set to be used for load shedding, then no control module in that zone will ever be forced into load shedding mode. If a zone is set to be used for load shedding, then before any control module in that zone can be forced into load shedding mode, the AC must receive a remote contact input status (which activates load shedding for that zone) from an external device ALARM RELAY RETURN TIME This parameter affects both the alarm and the warning relay driver outputs of the AC The ALARM RELAYS RETURN TIME defines the period of time for which the relay driver output will revert back to its normal state each time a new alarm is detected. When set to 0.0 seconds, the alarm/warning relay driver output will remain in its alarm/warning state until all active alarms/warnings have been reset. When set for any value greater than 0.0 seconds, the alarm/warning relay driver output will switch (and remain) in the alarm/warning state when the first alarm/warning is detected. When any subsequent alarm or warning is detected, the alarm/warning relay driver output will revert back to its normal state for the programmed ALARM RELAYS RETURN TIME. Once this time has expired, the alarm/warning relay driver output will return to its alarm/warning state until another alarm/ warning is detected, repeating the sequence. 56 / 81

57 7.4.5 CONTROL MODULE ALARM PRIORITIES The AC allows each alarm generated by a control module to be prioritized, as either a WARNING or an ALARM, according to its level of urgency. Any control module alarm with a WARNING priority will activate the WARNING relay driver output and turn on the WARNINGS LED on the front panel of the AC Any control module alarm with an ALARM priority will activate the ALARM relay driver output and the ALARMS LED on the front panel of the AC As well, each control module interfaced with an AC may be configured to use the GLOBAL configuration set of alarm priorities or its own LOCAL (control module specific) set of priorities. The following sections describe the difference between the LOCAL and GLOBAL settings. Control Module Global Alarm Priorities One GLOBAL configuration set of control module alarm priorities exists in each AC This allows all control modules interfaced to that AC to have the same priorities assigned to each of their alarms. Each GLOBAL control module alarm may be assigned either an ALARM or a WARNING priority. Set the control module s ALARM PRIORITIES parameter to GLOBAL if its alarms are to be prioritized using the GLOBAL configuration set. Control Module Specific Alarm Priorities If a control module is required to have any of its alarm priorities configured differently than the GLOBAL priority configuration set, then the ALARM PRIORITIES parameter must be set to LOCAL (or control module specific). Each alarm for that control module must then be prioritized as either a WARNING or an ALARM. For example, the user may wish to have the LOW TEMPERATURE ALARM in one control module prioritized as a WARNING and in all other control modules it may be prioritized as an ALARM AC ALARMS The AC has various operational alarms intended to provide information relative to certain functions of the AC Each of these alarms may be enabled or disabled in the AC configuration. The AC will not indicate any of these alarms unless that particular alarm is enabled. IMPORTANT: Disabling an alarm after the AC is already indicating it will not clear it. The alarm must be reset in order to clear it. The following sections give details on each of the operational alarms available in the AC GCC Reset Alarm The GCC RESET ALARM is a latched advisory alarm that indicates that the power to the AC has been removed and restored. If enabled, the GCC RESET ALARM will be active on power-up. Alarm Queue 80% Full Alarm The ALARM QUEUE 80% FULL ALARM is a latched advisory alarm that informs the user that the alarm queue, which can hold approximately 200 active alarms at once, has logged 160 alarms and is almost full. Alarm Queue 100% Full Alarm The ALARM QUEUE 100% FULL ALARM is a latched advisory alarm that informs the user that the alarm queue is full. Any additional alarms will displace previously logged alarms in the alarm queue. IMPORTANT: While control module alarms may be dropped from the AC alarm queue if it becomes full, the alarm will still be active at the control module. The AC will log the alarm again as soon as space becomes available in the alarm queue. Configuration Lost Alarm The CONFIGURATION LOST ALARM is a latched advisory alarm that informs the user that the AC s non-volatile memory was corrupted and has been reloaded with a default configuration. The list of installed control modules will be empty and each control module must be reinstalled. If this alarm occurs the STATUS LED on the front panel of the AC will flash green and red. This is another indicator to the user that a default configuration has been loaded and that communications with the AC may not function properly. The only method to reset this alarm is to modify at least one of the communication parameters using the method described in Section 7.2. IMPORTANT: Even though the list of installed control modules will be empty, control module configuration data will not be affected as a result of this alarm, as it is stored in the control module s own non-volatile memory. 57 / 81

58 HTC Carrier Failed On Alarm The HTC CARRIER FAILED ON ALARM is a latched advisory alarm that indicates that the AC has detected an unexpected data carrier from a control module and is unable to communicate on the HTC communication port. IMPORTANT: This is an indication of a problem with a control module and not a problem with the AC Remote Contact Timeout Alarm The REMOTE CONTACT TIMEOUT ALARM is a latched advisory alarm indicating that the remote contact input status, used for load shedding, has not been received by the AC from an upstream device, at least once every 60 seconds. This alarm can only be enabled if the LOAD SHEDDING CONTROL parameter of the AC is enabled and at least one zone is set to be used for load shedding. Load Shedding Alarms Each of the four load shedding zones has its own LOAD SHEDDING ALARM. These latched advisory alarms indicate that the AC is issuing a load shedding command for that particular zone. The AC can only indicate a LOAD SHEDDING ALARM for a particular zone if it has received a remote contact input status from an external upstream device indicating that that zone should be put into load shedding mode. Also, each zone s LOAD SHEDDING ALARM can only be enabled if the LOAD SHEDDING CONTROL parameter is enabled and that zone is set to be used for load shedding AC ALARM PRIORITIES Each of the AC operational alarms described in Section may be assigned either a WARNING or an ALARM priority, according to its level of urgency. Any alarm with a WARNING priority will activate the WARNING relay driver output and WARNINGS LED on the front panel of the AC Any alarm with an ALARM priority will activate the ALARM relay driver output and ALARMS LED on the front panel of the AC IMPORTANT: Switching an alarm priority after the AC is already indicating an active alarm will not alter how it is indicated. The alarm must be reset and then detected again in order for the AC to alter the indicated priority. 7.5 REMOTE DATA ACCESS The AC will continuously scan all installed control modules for active alarms. If an active alarm is detected, it will be indicated to an external upstream device and on either the ALARMS or WARNINGS LEDs on the AC s front panel. See Section 3.5 of this manual for details on each of the alarms that a control module may generate. The AC also maintains a copy of the configuration parameters for each installed control module in an internal database. An external up-stream device may access this internal database to read or modify the configuration parameters via any one of the AC s communication ports. See Section 3 of this manual for details on the control module s configuration parameters. For additional documentation on how to use the Modbus protocol to access the AC s internal database, see Section The data from any installed control module may also be monitored in real time by an external upstream device via any one of the AC s communication ports. The AC will first test to ensure that it can communicate properly with the selected control module. If there is an error, an alarm will be generated describing the problem. See Section 4 of this manual for details on the control module s measured and calculated parameters. 58 / 81

59 7.6 AC ALARMS WHAT TO LOOK FOR The AC alarm/communications interface card has various operational alarms intended to provide information relative to certain functions of the AC Each of these alarms may be selectively enabled or disabled to allow the monitoring and indication of trouble conditions. The following describe the different alarm conditions available on the AC 2000+, their meaning and possible causes. Alarm Description Cause of Alarm GCC Reset This alarm is latched when power is restored to the Circuit breaker tripped or shut off AC after an interruption. It is used to identify intermittent power losses. Power line transient Alarm Queue 80% Full Alarm Queue 100% Full Configuration Lost HTC Carrier Failed On This alarm is latched when the internal alarm queue, which holds approximately 200 active alarms, has logged 160 alarms and is almost full. This alarm is latched when the internal alarm queue is full. This alarm is latched when the AC s nonvolatile memory was corrupted and has been reloaded with a default configuration. This indicates that the AC communication port parameters must be reconfigured and the list of installed control modules must be re-entered. This alarm is latched when the AC detects a constant data carrier signal on its communication bus with the control modules. Alarms logged by control modules are not being reset Control modules are not configured correctly and are logging too many alarms A common condition exists which is causing many control modules to log alarms Alarms logged by control modules are not being reset Control modules are not configured correctly and are logging too many alarms A common condition exists which is causing many control modules to log alarms AC s internal configuration file was deleted or became corrupted At least one control module is constantly transmitting and is locking up the HTC communication port Remote Contact Timeout Load Shedding Zone Alarms This alarm is latched when the AC does not receive a remote contact input status message from an external upstream device at least once every 60 seconds. When any of the four load shedding zones are activated by receiving a remote contact input status message from an external upstream device, their corresponding load shedding alarm is latched. The external upstream device is not connected to the AC The external upstream device is not powered up The external upstream device is not configured to send a remote contact input status message The external upstream device does not send a remote contact input status message often enough The external upstream device wants a particular zone to be put into load shedding mode. 59 / 81

60 SECTION 8 MAINTENANCE 8.1 OPERATOR MAINTENANCE The DigiTrace T2000 HTC is designed to be a virtually maintenance free. Once installed properly the only maintenance required is re-tightening of any screw terminal connections approximately one week after installation and inspection periodically thereafter. Optional alarm pilot lamps (if installed) may need periodic replacement. WARNING: Make sure that the power to the DigiTrace T2000 HTC is OFF when replacing any pilot lamps! Also, be certain the power is OFF to the DigiTrace T2000 HTC before attempting to test or service the heat tracing. Do not rely on a control module as a disconnect device! 8.2 REPLACEABLE PARTS There are no user serviceable parts in the components of the DigiTrace T2000 HTC (except lamps in the optional alarm pilot lights). The unit is designed to be modular and easily changed out in the field in a matter of minutes. DigiTrace T2000 HTC components appearing inoperative should be returned to Pentair Thermal Management for service. IMPORTANT: Tampering with a DigiTrace T2000 component without approval from Pentair Thermal Management could result in voiding the product warranty. 60 / 81

61 APPENDIX A SPECIFICATIONS A1 DigiTrace T2000 HTC Specifications Storage ambient 40 F to 185 F ( 40 C to 85 C) Approvals CSA C/US Certified & FM Approved Classification Using CT 2000-HAZ : Class I, Division 2, Groups A,B,C,D Using CT 2000 : Ordinary Locations A2 CT 2000 Current Transformer Module Specification Operating Ambient 40 to 158 F ( 40 to 70 C) CT Module Output SPST EMR 3 A 240 VAC 70 C) Terminal Strip 14 AWG Max. / 10 A Max. Current Transformer 1000:1, 60 A Max. Ground Fault Current 1000:1, 20 to 100 ma Transformer A3 CT 2000-HAZ Current Transformer Module Specification Operating Ambient 40 to 158 F ( 40 to 70 C) Terminal Strip 14 AWG Max. / 10 A Max. Current Transformer 1000:1, 60 A Max. Ground Fault Current 1000:1, 20 to 100 ma Transformer A4 CR 2000 Card Rack Specification Operating Ambient 40 to 149 F ( 40 to 65 C) Capacity One(1) AC 2000 or AC Alarm/Communications Interface Card. Up to Ten(10) CM 2000 or CM Control Modules Terminal Strip 12 AWG Max. / 15 A Max. A5 CR Card Rack Specification Operating Ambient 40 to 149 F ( 40 to 65 C) Capacity One(1) AC 2000 or AC Alarm/Communications Interface Card. Up to Ten(10) CM 2000 or CM Control Modules Terminal Strip 12 AWG Max. / 15 A Max. Ethernet connector RJ-45 connector for 10Base-T Ethernet port. A6 CM 2000 Control Module Specifications Operating Ambient 40 to 149 F ( 40 to 65 C) Control Modes Deadband Mode: adjustable 5 to 90 F (3 to 50 C) above setpoint. Proportional Mode: bandwidth ± 2 F (± 1 C) Control Output +12 VDC nominal, 50 ma Max. Sensor Inputs Two(2) 3-wire 100 ohm Platinum RTDs (DIN 43760, a= w/w/ C) open/shorted sensor detection/protection, lead resistance compensation up to 20W per lead max. Power Requirements 90 to 240 VAC, 60 Hz, 1 Ph Power Consumption < 5 watts typical Temperature 58 to 999 F (-50 to 570 C), accuracy: ± 0.5% of span ± 1 LSD Measurement Range Voltage 90 to 280 VAC, 60 Hz, accuracy: ± 5% of span ± 1 LSD Measurement Range Current 0.3 to 50 A, accuracy: ± 2.5% of reading ± resolution, Measurement Range where resolution = 0.1 A (0.3 to 6 A range), 0.3 A (6 to 40 A range), 0.6 A (40 to 50 A range) repeatability: ± 3% of reading ± resolution 61 / 81

62 Ground Fault Measurement Range 20 to 100 ma, accuracy: ± 5.0% of span ± 1 LSD at nominal load, repeatability: ± 10% of reading A7 CM Control Module Specifications Operating Ambient 40 to 149 F ( 40 to 65 C) Control Modes Proportional, Deadband, Proportional Ambient SSR, Proportional Ambient Contactor modes, adjustable 2 to 90 F (1 to 50 C) Control Output +12 VDC nominal, 50 ma Max. Sensor Inputs Two(2) 3-wire 100 ohm Platinum RTDs (DIN 43760, a= w/w/ C) open/shorted sensor detection/protection, lead resistance compensation up to 20W per lead max. Power Requirements 120 to 240 VAC nominal, 50 ± 2 Hz or 60 Hz ± 3 Hz, 1 Ph, 5W Max. Temperature 76 to 1058 F ( 60 to 570 C), accuracy: ± 0.5% of span ± 1 LSD Measurement Range Voltage 80 to 295 VAC, 50/60 Hz, accuracy: ±1% of span ± 2 LSD, Measurement Range repeatability: ± 1.5% of span Current 0.3 to 100 A, accuracy: ± 2.5% of reading ± resolution where Measurement Range resolution = 0.1 A (0.3 to 11 A range), 0.3 A (11 to 40 A range), 0.7 A (40 to 100 A range) repeatability: ± 3% of reading ± resolution Ground Fault 20 to 100 ma, accuracy: ± 2.5% of span ± 2 LSD at Measurement Range nominal load, repeatability: ± 4% of span A8 AC 2000 Alarm/Communications interface Card Specifications Operating Ambient 40 to 149 F ( 40 to 65 C) Alarm Output SPDT Hermetically sealed relay, A Max. Alarm status LED Communications Modified Bell 103 FSK, 300 baud 2-wire half -duplex communications, isolated to 250 VAC, transient/open/short circuit protected Receive, Carrier, Transmit, and Req To Send status LEDs Control Module CM 2000 or CM Control Modules: 40 Controllers baud Communications Power Requirements VAC, 60 Hz, 1Ph Power Consumption < 5 watts typical A9 AC Alarm/Communications Interface Card Specifications 25 C and rated voltage unless otherwise noted and subject to change without notice) Operating Ambient 40 to 149 F ( 40 to 65 C) Approvals CSA (C/US) Certified & FM Approved Classification Class I, Division 2, Groups A,B,C,D T-code: T4A and Ordinary Locations Output Devices Individual N.C. Alarm and Warning relay drive outputs ma Max. Alarms and Warnings status LEDs Communications Local Port : RS-485 mode Non-Isolated, 2-wire, 32 devices Max. 300 to 9600 baud Modbus RTU/ASCII protocols, selectable paged (GCC/780 compatible or linear mapping Receive and Transmit status LEDs Local Port: RS-232C mode DE9S connector, DCE pinout 300 to 9600 baud Modbus RTU/ASCII protocols, selectable paged (GCC/780 compatible) or linear mapping 62 / 81

63 Control Module Communications General Receive and Transmit status LEDs Remote Port: RS-485 Isolated to 250 VAC, 2-wire, 32 devices Max. 300 to 9600 baud Modbus RTU/ASCII protocols, selectable paged (GCC/780 compatible) or linear mapping Receive and Transmit status LEDs Ethernet Port Modbus/TCP protocol Selectable paged (GCC/780 compatible) or linear mapping 10Base-T Ethernet User configurable IP Address, Netmask settings Link and Activity status LEDs CM 2000 Control Modules: baud CM Control Modules: baud VAC nom., 20% + 10%, 50/60 Hz, 10 W Max. Status LED: Red = Error, Yellow = Configuration mode, Green = Run/Normal A10 - Maximum Distances for RS-485 Communications The following chart shows typical distances that may be achieved using the RS-485 communication ports. These distances are based on using a 2-wire, 26-AWG shielded twisted pair. Note that speed and distances will depend on actual operating conditions. Speed Distance 1200 bps 4.00 miles (6.4 km) 2400 bps 3.00 miles (4.8 km) 4800 bps 2.30 miles (3.7 km) 9600 bps 1.70 miles (2.7 km) The RS-485 converter used at the PC end may be an internal card that plugs into one of your computers empty slots, or an external device that connects to one of the existing serial ports via a cable. It is strongly recommended that you use an isolated-type interface to protect the computer from any voltage transients that may be introduced into the field wiring. 63 / 81

64 APPENDIX B DIGITRACE T2000 HTC COMPONENT WIRING DIAGRAMS B.1 CONTROL MODULE / CT 2000 CONTACTOR WIRING DIAGRAM TO TRACING VAC 50/60Hz LINE IN 1 T2000 CONTROL MODULE F C TEMP CURRENT SETPT OUTPUT ALARM TRANSMIT RECEIVE CONTROL + CONTROL - CURRENT CT CT COMMON GFI CT CT SHIELD RTD SHIELD RTD1 SOURCE RTD1 SENSE CONTACTOR CONTROL + CONTROL - LOAD CT CT COMMON GFI CT LINE OUT CT 2000 CT MODULE ADDRESS 10 RTD1 COMMON 11 RTD2 SOURCE CM RTD2 SENSE RTD2 COMMON 120/208/240 VAC COIL CONTACTOR RTD1 100 Ohm Platinum DIN D RTD1 100 Ohm Platinum DIN FROM DISTRIBUTION PANEL 64 / 81

65 B.2 CONTROL MODULE / CT 2000-HAZ SINGLE POLE SSR WIRING DIAGRAM TO TRACING UNUSED 1 T2000 CONTROL MODULE F C TEMP CURRENT SETPT OUTPUT ALARM TRANSMIT RECEIVE CONTROL + CONTROL - CURRENT CT CT COMMON GFI CT CT SHIELD RTD SHIELD RTD1 SOURCE RTD1 SENSE UNUSED UNUSED UNUSED LOAD CT CT COMMON GFI CT UNUSED CT 2000-HAZ CT MODULE ADDRESS 10 RTD1 COMMON 11 RTD2 SOURCE CM RTD2 SENSE 13 RTD2 COMMON SSR RTD1 100 Ohm Platinum DIN D RTD1 100 Ohm Platinum DIN FROM DISTRIBUTION PANEL 65 / 81

66 B.3 CONTROL MODULE / CT 2000-HAZ TWO POLE SSR WIRING DIAGRAM TO TRACING UNUSED 1 T2000 CONTROL MODULE F C TEMP CURRENT SETPT OUTPUT ALARM TRANSMIT RECEIVE CONTROL + CONTROL - CURRENT CT CT COMMON GFI CT CT SHIELD RTD SHIELD RTD1 SOURCE RTD1 SENSE UNUSED UNUSED UNUSED LOAD CT CT COMMON GFI CT UNUSED CT 2000-HAZ CT MODULE ADDRESS 10 RTD1 COMMON 11 RTD2 SOURCE CM RTD2 SENSE 13 RTD2 COMMON SSR SSR RTD1 100 Ohm Platinum DIN D RTD1 100 Ohm Platinum DIN FROM DISTRIBUTION PANEL 66 / 81

67 B.4 AC 2000 ALARM / COMMUNICATIONS INTERFACE CARD WIRING DIAGRAM 1 L1/LINE TRACER 2000 ALARM COMMUNICATIONS INTERFACE 2 3 L2/NEUTRAL RECEIVE CARRIER TRANSMIT REQ TO SEND ALARM AC GROUND ALARM N.O. RELAY COM. ALARM N.C. SIG + SIG - TX/RX + TX/RX - RTS/DCD+ RTS/DCD MODEM MODEM SHIELD ALARM RELAY CONTACTS 0.5A MAX. 240VAC TERMINALS 9 THROUGH 14 ARE ONLY USED TO CONNECT COMMUNICATIONS FROM ONE CARD RACK (CR2000) TO THE PREVIOUS UNIT ISOLATED MODEM COMMUNICATIONS MODEM COMMUNICATIONS CONNECTIONS FOR CR2000 TERMINATION RESISTORS ARE USED WHEN ONE CARD RACK IS USED ON ITS OWN, OR FOR THE LAST CARD IN THE GROUP INTERCONNECTIONS BETWEEN MULTIPLE CARD RACKS FOR COMMUNICATIONS SHIELD SIG + SIG - TX/RX + TX/RX - RTS/DCD + RTS/DCD K ohm RESISTOR 120 ohm RESISTOR 120 ohm RESISTOR SHIELD SIG + SIG - TX/RX + TX/RX - RTS/DCD + RTS/DCD - TO TERMINALS 9-14 OF THE NEXT CARD RACK D / 81

68 B.5 AC ALARM COMMUNICATIONS INTERFACE CARD WIRING DIAGRAM T2000 ALARM / COMMUNICATIONS CONTROLLER L1/LINE L2/NEUTRAL A T T T STATUS AC BASE-T ETHERNET REMOTE PORT L R R R ALARMS WARNINGS LAN REMOTE LOCAL HTC LOCAL PORT RS232 DCE 4 GROUND 5 ALARM N.C. 6 RELAY COM. 7 WARNING N.C. 8 SIG + 9 SIG - 10 TX/RX + 11 TX/RX - 12 RTS/DCD + 13 RTS/DCD - 14 REMOTE + 15 REMOTE - 16 SHIELD 17 ATC 18 LOCAL + 19 LOCAL - 20 ALARM/WARNING RELAY DRIVER +12VDC 100MA MAX. TERMINALS 9 THROUGH 14 ARE ONLY USED TO CONNECT COMMUNICATIONS FROM ONE CARD RACK (CR2000+) TO THE PREVIOUS UNIT REMOTE RS-485 COMMUNICATIONS LOCAL RS-485 COMMUNICATIONS TERMINATION RESISTORS ARE USED WHEN ONE CARD RACK IS USED ON ITS OWN, OR FOR THE LAST CARD IN THE GROUP INTERCONNECTIONS BETWEEN MULTIPLE CARD RACKS D FOR COMMUNICATIONS SHIELD SIG + SIG - TX/RX + TX/RX - RTS/DCD + RTS/DCD - ATC REMOTE + REMOTE - LOCAL + LOCAL - SHIELD K ohm RESISTOR 120 ohm RESISTOR 120 ohm RESISTOR 120 ohm RESISTOR 120 ohm RESISTOR SHIELD SIG + SIG - TX/RX + TX/RX - RTS/DCD + RTS/DCD - ATC REMOTE + REMOTE - LOCAL + LOCAL - SHIELD TO TERMINALS 9-14 OF THE NEXT CARD RACK D / 81

69 B.6 AC LOCAL PORT RS-232 CONNECTIONS T2000 ALARM / COMMUNICATIONS CONTROLLER STATUS ALARMS WARNINGS A L LAN T R REMOTE T R LOCAL T R HTC TO LOCAL PORT TO DTE RS-232 STRAIGHT THROUGH CABLE LOCAL PORT RS232 DCE AC MALE DB-9 FEMALE DB-9 B.7 EXTERNAL ALARM AND WARNING RELAY CONNECTIONS D T2000 ALARM / COMMUNICATIONS CONTROLLER ALARM/WARNINGS RELAY DRIVER mA MAX. ALARM RELAY A T T T STATUS ALARMS WARNINGS L LAN R REMOTE R LOCAL R HTC ALARM N.C. RELAY COM. WARNING N.C WARNING RELAY LOCAL PORT RS232 DCE AC BASE-T ETHERNET REMOTE PORT D / 81

70 B.8 CR 2000 CARD RACK TERMINAL ASSIGNMENTS D D / 81

71 B.9 CR 2000 REV. A CARD RACK TERMINAL ASSIGNMENTS D D / 81

72 B.10 CR CARD RACK TERMINAL ASSIGNMENTS D D / 81